Characterization of 3D metal printed cutting tool with transpiration cooling channels

Abstract

Abstract This study characterizes the 3D-printed transpiration cooling (TC) channels in a single-point cutting tool to enhance lubrication and cooling at the cutting zones. Five different TC channels, namely two circular profiled channels (Designs 1-A & 1-B), two hexagonal profiled channel (Designs 2-A & 2-B), and one bio-inspired blood vessel (Designs 3), are designed inside a single-point turning tool and 3D printed using AISI-1.2709 in powder bed fusion (PBF). From the materials and mechanical characterisation, fine cellular microstructure and high hardness are achieved. X-ray microcomputed tomography (XRμCT) has been used as a non-destructive inspection strategy to analyse the built structures. The results of XRμCT showed that the TC channel built is highly orientation-dependent, steeper angles deviate highly, and nominal angles such as 0° and 90° (to the build platform) provide the best dimensional accuracy. The average dimensional deviations of the five designs are −35.8%, −19.42%, −19.45%, −15.85%, and −5.02%, respectively, from the as-designed. The best designs are circular free-form (Design 1-B), hexagonal free-form (Design 2-B), and bio-inspired blood vessel (Design 3), which have the least dimensional deviation and highest accuracy.