Experimental and numerical analysis of the adapted high-pressure cutting fluid supply for turning AISI 1045 steel

In continuous cutting, the use of high-pressure cutting fluid supply improves fluid penetration at the tool/workpiece interface, improving heat dissipation and allowing higher cutting speeds for better machining efficiency. While prior research has mostly focused on the role of cutting fluid pressure, the influence of nozzle design on machining outcomes has not been thoroughly examined. This study explores the impact of various nozzle opening shapes and pressures on tool wear and workpiece surface roughness, utilizing additively manufactured nozzles. Findings indicate that chip morphology under the investigated cutting conditions is primarily influenced by cutting fluid pressure and is minimally affected by nozzle opening shape. In addition, the design of the flank face nozzle is crucial for optimizing surface roughness and extending tool life. The simulation results indicate that the difference in various flank face nozzles is due to changes in the flow velocity within the cutting zone.