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The high-pressure coolant is considered as a very important point to improve the machining performance. Most of the papers concern the effect of high-pressure coolant on titanium where its efficiency is very important. This paper investigates the application of a high-pressure lubricant during the turning of stainless steel using coated carbide tools to control the chip size through an extensive experimental work. The effects of the cutting conditions, the cutting tool geometries, and the lubricant pressure were studied. A model was developed to clearly understand the mechanical effects of a lubricant on the chip fragmentation. This model is partially based on a Maln experimental analysis in which a high-speed camera was used to define the jet geometry. Finally, the relationship between the cutting conditions and the pressure is meticulously described. [ABSTRACT FROM AUTHOR]

Since the 1960s, the Inconel Alloy 718 has been a standard nickel-based superalloy due to its high strength, balanced mechanical properties, and strong corrosion resistance at relatively low costs and has been widely used in critical aircraft engine components. With the aim of improving productivity and product quality by implementing advanced tools and new process designs, models such as the FE model are utilized to predict the machining performance such as the cutting forces, the tool life, and the surface integrity. In the research area of FEM chip formation simulation, the influence of flank wear on predictions has not been investigated, especially not on the underestimation of the cutting normal force. In this paper, a 2D FEM chip formation model with the coupled Eulerian-Lagrangian (CEL) method has been built to predict cutting forces as well as other material loadings (Brinksmeier et al. Procedia CIRP 13:429–434, 2014; Buchkremer and Klocke Wear 376-377:1156–1163, 2017) in the machining of Direct Aged 718. In order to validate the performance of the FE model, fundamental investigations have been performed in orthogonal cutting with different cutting parameters. Two kinds of cemented carbide cutting tools with different cobalt contents have been applied to achieve different tool wear behaviors. Moreover, the underestimation of the cutting normal force by FEM chip formation simulation has been investigated and solved in consideration of the flank wear. The introduced FE-modeling approach shows precise predictions in terms of the cutting forces and the chip formation. [ABSTRACT FROM AUTHOR]