A new coolant supply for solid end mills in HRSA alloy machining

Abstract

Nickel-based alloys like Inconel718 are crucial in aerospace for their strength and resistance to thermal fatigue and corrosion, but they are difficult to machine due to rapid tool wear and high cutting forces. This study introduces a novel coolant design with holes connecting adjacent flutes. The new design helps to reduce flank wear thanks to better fluid flow around the cutting edge, as verified by CFD simulation. Experimental results showed that the new coolant system outperforms conventional methods, particularly when the tool wear is thermal driven. These demonstrate the potential of advanced coolant system to enhance the machinability of Inconel718.