Capability of high pressure cooling in the turning of surface hardened piston rods

An experimental study was performed to investigate the capabilities of dry, conventional and high pressure cooling (HPC) in the turning of surface hardened piston rods used in fluid power applications. Machining experiments were performed using coated carbide tools at cutting speeds up to 160 m/min. The cooling capabilities are compared by monitoring of chip breakability, process regions of operability, cooling efficiency, tool wear, tool life and cutting forces. Test results showed that dry cutting could not be performed due to long and ductile chips that were formed for all investigated cutting conditions. In comparison to conventional cooling the significant increase of cutting speed and feed rate region of operability was recorded when machining with HPC. Tool life analysis proved a five times increase in tool life when machining with HPC. Furthermore HPC also improved chip breakability and reduced coolant consumption.