The Design and Performance of Internally Cooled Cutting Tools for Turning: A Literature Review

Abstract

Near–dry machining and dry machining lead to increased temperature of the cutting tools. To reduce tool wear and extend the tool lifetime, and, eventually, to keep the accuracy of manufactured parts within acceptable limits as long as possible, a sustainable cooling technique is required. The technology of internal cooling of the cutting tool appears to be the most promising, because it allows eliminating the presence of the coolant on the manufacturing part and delivers the heat–transferring fluid to the very cutting area of the tool. This paper provides a literature review on the closed–loop internally cooled cutting tools (CLICCT) for turning. The current level of knowledge and experimental machining with prototypes has proven that CLICCT can utilize the benefits of dry cooling, having a longer tool life.

Full text

73
LATVIAN JOURNAL OF PHYSICS
AND TECHNICAL SCIENCES
2023, N 5
DOI: 10.2478/lpts-2023-0032
THE DESIGN AND PERFORMANCE OF INTERNALLY
COOLED CUTTING TOOLS FOR TURNING:
A LITERATURE REVIEW
A. Korenkovs*, E. Gerins, A. Kromanis
Faculty of Mechanical Engineering, Transport and Aeronautics,
Riga Technical University,
6B Ķīpsalas Str., Riga, LATVIA
*e-mail: arturs.korenkovs@edu.rtu.lv
Near–dry machining and dry machining lead to increased temperature of the cutting tools.
To reduce tool wear and extend the tool lifetime, and, eventually, to keep the accuracy of
manufactured parts within acceptable limits as long as possible, a sustainable cooling tech-
nique is required. The technology of internal cooling of the cutting tool appears to be the most
promising, because it allows eliminating the presence of the coolant on the manufacturing part
and delivers the heat–transferring uid to the very cutting area of the tool. This paper provides
a literature review on the closed–loop internally cooled cutting tools (CLICCT) for turning.
The current level of knowledge and experimental machining with prototypes has proven that
CLICCT can utilize the benets of dry cooling, having a longer tool life.
Keywords: Closed–loop internal cooling, dry machining, internally cooled cutting tool,
near–dry machining, turning.

Dry cutting due to the non-use of cool-
ants is environmentally friendly and has
become an important feature in today’s
green manufacturing [1]. The removal
of metal working uids (MWF) from the
machining processes is of benet to the
machine operator, swarf recycling, and ulti-
mately the environment [2]; it also reduces
coolant–related costs [3].
Based on the environmental impact and
health care, dry cutting is the best method
of cutting, but it has some limitations, espe-
cially with the hard-to-cut material, where a
large amount of heat is generated [4].
Dry machining (DM) leads to increased
cutting temperatures and higher wear rates
resulting in shorter tool life; this is particu-
larly evident in the cutting of high-strength

74
materials [5]. In the machining of special
materials such as rocket solid fuel, the cut-
ting temperature must be strictly controlled;
otherwise, it would explode and result in an
accident [6]; also machining sensitive mate-
rials for optics or bio-medical applications
or when machining harmful materials such
as radioactive materials [7]. The internal
coolant is sucient to reduce the cutting
temperature and avoid critical cutting tem-
peratures [8].
Dry machining technology can be clas-
sied as near-dry cutting (NDC) and dry
cutting [9].
Several cooling techniques are used
for near–dry machining and dry machining
(DM), such as minimum quantity lubrica-
tion (MQL) [10]; high-pressure cooling
[10]; compressed air/vapor/gas cooling [9];
cryogenic cooling (liquid nitrogen) [11]–
[14]; cryogenic MQL [15], [16]; internal
cooling (heat sinks [5], heat exchangers [5],
vortex tubes [5], heat pipes [5], pulsating
heat pipes [17]–[19]; open circuit internal
cooling [20].
The combination of cooling methods
is also used: heat pipe and internal cool-
ing [21], closed circuit internal cooling
and spray cooling [22]–[26], closed circuit
internal cooling and external MQL [27],
and micro-texture self-lubricating tool with
pulsating heat pipes [17].
Closed-loop internally cooled cut-
ting tool (CLICCT) utilizes the benets of
internal cooling more fully because there
is no contact between the cooling uid and
machined part, coolant might be reused,
and it has no inuence on the operator.
The aim of this paper is the literature
review of the scientic articles dedicated
to the development and research of inter-
nally cooled cutting tools (ICCT) for dry
machining (DM), with the particular scope
of research – closed-loop internally cooled
cutting tools (CLICCT) for turning.

The research of the literature consists of
reviewing publicly available scientic pub-
lications, using abstract and citation online
database Scopus.
The search for English language publi-
cations corresponding to the tag “internal
cooling cutting tool” resulted in a list of 199
nal publications, which was reduced to 68
articles by applying keyword lters (“cutting
tools”, “internal cooling”, “turning”) (see
Fig. 1). Similarly, the search for “internally
cooled cutting tool” resulted in the list of 43
publications, and was reduced to 10 (lter
keywords: turning, internally cooled cutting
tools); the search for “indirect cooling cut-
ting tool” resulted in the list of 14 articles;
the search for “cryogenic internal cooling”
resulted in the list of 369 publications, and
was reduced to 4 articles (lter keywords:
cutting tools, turning); and the search for
“dry turning internal cooling” resulted in the
list of 34 articles, and was reduced to 12 (l-
ter keywords: cutting tools).
The search for “internal cooling cutting
tool” (with corresponding keyword lters
applied) results in 68 articles – the most full
list of scientic publications dened as a part
of this review. This list states that there were
4 articles published before 1990, 2 articles
in the period of 1990–2000 (0.2 articles per
year on average), 3 articles in 2000–2010
(0.3), 42 articles in 2010–2020 (4.2), and 11
articles in 2020–2022 (5.5). That indicates
an increase in the average number of publi-
cations per year about internally cooled cut-
ting tools (ICCT), particularly since 2000.

75
Fig. 1. Total number of publications by year based on searched keywords and applied lters.
Due to keyword matching, some articles
appeared in more than one search. Leaving
only publicly accessible articles, whose
scope of research ts the denition of ICCT
for turning, the total number of selected
articles is equal to 54.
25 articles [1], [2], [5]–[7], [12], [22],
[23], [28]–[46] out of the 54 selected arti-
cles cover dierent designs of CLICCT, 5
articles [6], [29], [36], [38], [43] cover only
the FE and CDF simulations of CLICCT
and 18 articles describe experimental turn-
ing with CLICCT prototypes [1], [2], [5],
[7], [12], [28], [30], [32]–[34], [35], [37],
[39], [41], [42], [44]–[46] (see Fig. 2).
Fig. 2. Arrangement of selected publications by eld of research.
In 6 articles [6], [30], [35], [37], [41],
[44] the CLICCT design was dened as
“novel” and in 1 article [42] as “innova-
tive”.

76

INTERNALLY COOLED CUTTING TOOLS FOR TURNING
The design of CLICCT consists of CT
itself and the coolant supply and circula-
tion system. A schematic view of CLICCT
proposed by Zakaria et al. [44] is shown in
Fig. 3 and represents the main components
of the cooling circuit: coolant tank, pump
and hoses (tubes or pipes), and ow meter.
The purpose of the ICCT, apart from
forming the cutting edge of the tool, is to
deliver the coolant and remove the heat
from the tool–chip contact area of the tool.
The internal cooling can be provided
by dierent geometric patterns such as pro-
viding tiny grooves beneath the toolholder,
providing the chamber under the shim of the
toolholder, and designing proles by utiliz-
ing the maximum area of cross-section [8].
The design of ICCT proposed by Shu et
al. [31] is shown in Fig. 4 and represents the
ICCT for turning with a cooling chamber
(formed between standard cutting insert and
support seat), where the coolant is supplied
to support seat through the micro holes in
the toolholder.
One of the main drawbacks of internally
cooled tools with closed circuit ow is their
complicated manufacturing [48].
Ghani et al. [50] in their research con-
sider that the issue in improving the design
of the internally cooled cutting tool is that
the internally cooled cutting tool cannot
be manufactured by using a conventional
machine due to the complex shape of the
cooling channel. In the research [50], [51]
the use of additive manufacturing technolo-
gies in the manufacturing of ICCT was
studied, concluding that: the selective laser
melting (SLM) process provided higher
precision and had a better surface roughness
than the direct metal laser sintering (DMLS)
process, but, the DMLS process performed
better in dimensional accuracy than SLM
[50]; and that the SLM could produce ICCT
with high relative density (99 %) and low
surface roughness (4.61 μm), showing min-
imum microstructure defects that encour-
aged the internal channel design [51].
Fig. 3. Schematic view of the closed loop internally cooled cutting tool for turning [44].

77
Fig. 4. Schematic view of the smart cutting tool [31].
The availability of modern machining
and manufacturing technologies, accurate
measuring instruments, precise computing
and simulating software allows reaching
the designed accuracy of the CT, establish-
ing a tool condition monitoring system for
adjustment of the operating parameters in
real time, and development of smart cutting
tools.
The temperature-based smart cutting
tool focuses on the development of the
internally cooled cutting tool, reducing the
cutting temperature around the cutting edge,
in order to extend tool life and produce a
better surface nish at the workpiece [53].
The cutting tool can be also used as a smart
tool by sensoring the cutting tip tempera-
ture in real time by continuously measuring
the cooling inlet and outlet temperatures,
and correlating them through a smart algo-
rithm [47]. Articial Neural Networks can
be used to predict the underlying non-linear
trends in tool temperature data obtained
over a range of machining conditions [49].
The concept of an internally cooled
smart cutting tool (ICSCT) for turning with
closed-loop cooling circuit was proposed
in [6] and realized in [30]. The authors of
the research [41] proposed to use thermo-
couples for real-time measurement of cool-
ant inlet and outlet temperatures, and cool-
ant ow rate control system, for developing
adaptive control machining, where abnor-
mal temperature rising of the cutting tool
and thus tool wear could be avoided and
adaptively controlled.
The performance of the dierent designs
of CLICCT can be predicted with the help
of FE and CFD simulation software.

CFD SIMULATIONS FOR ICCT FOR TURNING
Turning tools with closed internal cooling
systems must meet a dierent set of require-
ments compared to conventional tools. In
particular, they must ensure the mechanical
stability of the deployed cooling medium
[52]. The research [54] on the prole congu-
ration of the internal cooling channels in cut-
ting insert concludes: the provision of internal
cooling channel increases the cooling eect
by decreasing the temperature; the variation

78
of the prole structure leads to temperature
dierence; the heat transfer rate of the uid
depends upon the prole structure [54].
Computational uid dynamics (CFD)
software allows simulating the ow of cool-
ing uid inside the internal channels of the
tool and predicting the performance of the
tool, i.e. the temperature of the tool–chip con-
tact area, and eventually developing a tool
design that meets the set of specic require-
ments for CLICCT.
In the scope of selected scientic articles,
the researchers used dierent approaches for
the IC simulation of CT.
Shu et al. [6] conducted a simulation test
of the smart cutting tool with closed–loop
internal cooling. The simulation imitates
machining with and without internal cool-
ing (see Fig. 5). The authors concluded that
the proposed micro internal structure could
substantially decrease the tool temperature
of the cutting process (from 381.62 ˚C to
273.9 ˚C) and that the temperature of the
tool tip might be estimated by measuring
the coolant inlet and outlet temperature; as
well as the simulations showed that a wall
thickness of 1 mm towards the rake face
and a minimum wall thickness of 0.7 mm
towards the ank face were sucient to
withstand the mechanical loads [6].
Fig. 5. Examples of tool temperature contours and velocity vector (a) without internal cooling,
(b) with internal cooling, (c) velocity of cooling liquid [6].
Saiful et al. [29] simulated a water jet
impingement cooling of a commercially
available CI with a designed internal micro-
channel varying three parameters (space
between the channel and internal wall
of the insert, channel diameter, and uid
temperature). Researchers concluded that
internal cooling could reduce the cutting
temperature by more than 50 ˚C (compared
to DM), the minimum cutting temperature
was achieved when the cooling uid tem-
perature was low, and the space between the
channel and the internal wall of the insert
was high [29].
Zakaria et al. [36] carried out a FEM
simulation test to dene the eect of cutting
load exerted on the modied tool holder
(made of alloy steel, cubic boron nitride,
and cemented carbide) with internal cooling
channels (with diameters of 1.6, 4.2, and
5.0 mm) during the turning process of tita-
nium alloy and aluminium. The researchers
concluded that the application of the inte-
grated cooling inside the tool holder led
to the weakening of tool holder strength
consequent of porosity forming; displace-
ment of the tool holder was proportionally
increased with incremental of hole diameter
size, and maximum stress occurred at the x
mounted end, whose value of stress should
not exceed the Young Modulus value [36].
Li et al. [38] used a thermal topologi-

79
cal optimization model of the insert plane to
evaluate the mechanical properties and heat
transfer of CT, simulating DM and machin-
ing with two dierent types of ICCT. Among
other things, the authors concluded that the
proposed optimization model was suitable
for ICCT design to determine the layout of
the ow channel and that the topological
conguration design performed well both in
the mechanical and thermal analysis (maxi-
mal stress of the topologically designed tool
was 7.6 % higher, and maximum displace-
ment was 6.5 % higher, but the maximum
temperature was 6.2 ˚C lower, compared to
traditional congured ICCT; and 180.4 ˚C
compared to DM with non-cooled CT) [38].
Uhlmann and Meier [43] performed
a numerical investigation of the heat ow
with consideration of the thermomechani-
cal load of the ICCT (with tool thickness
of 1.58 mm and 4.76 mm) and ow char-
acteristics of the cooling liquids (water and
water–glycol at various temperatures and
ow rates). They concluded that the process
behavior showed a dependence of the ow
rate (the inlet coolant temperature became
less important with increased ow rate)
and tool thickness (which shall be mini-
mized under simultaneous consideration of
the mechanical tool load) in terms of tool
temperature reduction (reaching maximum
simulated tool temperature reduction value
equal to 193 ˚K, at –10 ˚C water/glycol inlet
temperature and 10 l/min ow rate) [43].
More publications consist of computa-
tional simulation of IC and actual experi-
mental machining.


The conditions of the experiments to
the fullest extent possible are described in
the reviewed publications. In this paper,
only the main aspects of published experi-
ments are mentioned.
Vicentin et al. [28] machined SAE
J775 XEV-F steel with the experimental
CLICCT (cooled with R-123 refrigerant)
with a cemented carbide CI (with triple
layer coating) and compared the results of
IC machining with DM and machining with
external cutting uid cooling (three cutting
tools were used for each cooling method).
The research among other things resulted
in conclusions that internal cooling oered
clear economic gains mainly in the increase
of tool life (compared to DM), and was
competitive once the costs involved with
cutting uids was a signicant part of the
piece total costs (compared to external cut-
ting uid cooling) and that the proposed IC
system produced surface roughness values
noticeably lower than with dry machining
[28].
Uhlmann et al. [45] studied the inu-
ence of the coolant uid temperature on
the ank wear, performing the experi-
ment of machining aluminium alloy
AlSi7Mg0.3 with CLICCT (with custom-
ized 1.0 mm thick cemented carbide CI)
for turning, applying dierent temperature
coolant (20 ˚C and –10 ˚C) for dry and
wet machining conditions. The research
resulted in the conclusion that a decrease
in ank wear of 10 % could be achieved
by internal cooling (if wet machining was
considered a reference), and the wear could
be reduced by 32 % with coolant temper-
atures at 20 ˚C and by 20 % with coolant
temperatures at –10 ˚C (if DM was used as
a reference level); that IC increased qual-
ity by reducing surface roughness; and that

80
the ICCT had advantages for the machining
AlSi7Mg0.3 [45].
Minton et al. [5] experimented with the
machining of titanium 2 CP with CLICCT
under conditions of dry-machining and
inserted jet impingement cooling with eth-
ylene glycol (directed through micro mill-
ing machined steel cooling block with a
uid reservoir, inlet, and outlet channels),
with uncoated and diamond–coated (8 μm
medium thickness, crystalline, diamond
coating deposited via hot lament CVD)
tungsten carbide CI (with reduced thickness
to 1 mm). Researchers concluded that the
introduction of an internally cooled cutting
tool with enhanced thermal conductivity
showed an increased tool life over conven-
tional tools in DM of titanium (by approxi-
mately 41 % from 15 to 24 minutes of the
cutting process, depending on machining
conditions) and that the combination of the
heat-spreading layer and indirect cooling
provided an eective method of controlling
thermally induced wear [5].
Shu et al. [30] carried out numerical
modelling to optimize the design of CI
(simulating dierent mechanical load con-
ditions) and to evaluate the maximum tem-
perature of the tool, and performed experi-
mental machining aluminium alloy 6061-T6
(under dierent cutting conditions) with
the designed closed–loop ICSCT (cooled
with puried water; and consists of a tool-
holder with microholes, support seat with
an annular groove, reduced to 1.8 mm thick
tungsten carbide CI and thermocouples).
Researchers concluded that the proposed
average cutting temperature prediction
model (which evaluated the maximum tem-
perature of the tool equal to 442.28 ˚C for
DM and equal to 359.6 ˚C for IC) possessed
good accuracy and that there was a time lag
in the smart cutting tool system (because
the outlet temperature took time to reach
steady) [30]. The authors also suggested
that it was worthwhile to apply the smart
cutting tool for adaptive control machin-
ing, where abnormal temperature rising of
the cutting tool and thus tool wear could be
avoided and adaptively controlled [30].
Ferri et al. [7], as a part of the experi-
ment, machined AA6082–T6 aluminium
alloy (see Fig. 6) with purpose-built ICCT
(cooled by water with corrosion inhibi-
tor) with tungsten carbide CI (modied to
achieve squared bottle-cup shape). The sta-
tistical analyses showed that the measured
chip temperature appeared to depend sig-
nicantly only on the depth of cut but not
on the feed rate or the cutting speed [7].
Fig. 6. Experimental set-up of the internally cooled
tool on the CNC lathe: (a) pyrometer, (b) work-
piece, (c) coolant outlet, (d) cutting tool, (e) coolant
inlet [7].
Ferri et al. [2] machined aluminium
6082-T6 with CLICCT with tungsten car-
bide CI (modied with microuidic struc-
tures), measuring coolant (ethylene glycol
and water solution) inlet and outlet tem-
peratures, together with the cutting and the
thrust forces. The data analysis resulted in
the conclusion that the specic eciency

81
once log-transformed was found linearly
increasing with the depth of cut and feed
rate, and the maximum expected eciency
was equal to 10.96 % (at 0.10 mm/rev feed
rate and 250 m/min cutting speed) [2].
Neto et al. [46] carried out experimen-
tal machining of stainless steel SAE XEV-F
under internally cooled, externally cooled
(ooded) and dry cutting conditions with
designed CLICCT, with coated cemented
carbide CI, connected to a silver interface
in the annular channel of the tilted vaporiza-
tion chamber (for phase-changing coolant
Dupont R141b). Among other things, the
authors concluded that the internal cooling
method, compared to dry cutting, was less
damaging to the cutting tool and provided
a greater tool life, but the eectiveness of
that method, compared to the method with
applied cutting uid, was not satisfactory
(due to no lubricating action and lesser
cooling capacity) [46].
Neto et al. [32] performed a thermal
simulation for heat conduction analysis of
the cutting tool temperature prole (for DM
and IC conditions) and tested a CLICCT
with phase-change coolant (Dupont R141b),
and uncoated cemented carbide CI (contact-
ing silver interface), machining AISI 1045
steel, to compare the performance with dry
cutting and ood cutting conditions, dur-
ing continuous and interrupted turning. The
authors concluded that the IC was able to
extend the cutting tool lives by 5 8% and
13 % in relation to the cutting uid applica-
tion and dry cutting, respectively; and the
IC method was able to extend the cutting
tool lives by 7 % and by 45 % in relation
to the cutting uid application and cutting,
respectively; the temperatures recorded and
the results of the simulation demonstrated a
reduction of 10 % [32].
Isik [33] in his manuscript describes
a session of experiments of machin-
ing of nickel-based superalloy Wasp-
aloy AMS5708 with a designed CLICCT
(with CVD-coated carbide CI), which is
cooled by 18 ˚C puried water, at dierent
experimental conditions (dierent cutting
speeds). Isik [33], among other things, con-
cludes that compared with dry machining
IC decreases maximum tool–chip tempera-
ture by 9 %, reaches an extension of tool life
by 12 %, achieves up to 13 % better surface
quality (the lowest surface roughness value
was Ra=0.699 μm at a cutting speed of 95
m/min, an inlet velocity rate of 1.6 m/s, and
a depth of cut of 0.5 mm).
Sanchez et al. [34] developed a heat
conduction model and carried out simu-
lations (to estimate the temperature and
heat ux at any point of the cutting tool),
which followed by experimental machin-
ing of SAE J775 XEV-F steel with designed
CLICCT (cooling uid – refrigerant R22)
with a CI. The authors concluded that the
condition of steady state was reached in a
shorter time when using the internal cooling
and temperatures in the cutting region were
lower; the eectiveness of the toolholder
with internal cooling was only noticeable in
machining processes that exceeded the time
required to reach a steady state; and that in
relation to dry machining, the proposed sys-
tem oered clear economic gains mainly in
the increase of tool life (due to the smaller
rate of tool wear) [34].
Isik et al. [35] carried out nite ele-
ment analysis (to develop a temperature
simulation model) and testing of designed
CLICCT (water cooled) with CVD-coated
carbine CI, machining DIN 1.2379 cold
work die steel (50 HRC). Within the limits
of the experimental setup, the authors con-
cluded that internal cooling of CT decreased
the maximum temperature at the tool–chip
interface from 607 ˚C to 545 ˚C, provided
up to 12 % better surface quality (than
DM), extended tool life up to 15 % [35].
It was also concluded that the temperature

82
of the dierences between the inlet and out-
let decreased with the increase in the ow
rate and that the tool temperature could be
reduced by up to 11 % [35].
Yao et al. [37] carried out a numeri-
cal analysis of the thermal performance of
the designed water-cooled ICCT (to evalu-
ate tool temperature at various machining
conditions) and experimental machining
of carbon steel 1045 with the tool proto-
type (consisting of the toolholder with a
V-shaped cooling channel and carbide CI)
under IC and dry cutting conditions. They,
among other things, concluded that temper-
ature data measured during experimental
machining was highly consistent with those
of numerical simulations and that the inter-
nal cooling decreased the maximal temper-
ature at the measured point by almost 30 %
(compared with dry cutting) [37].
Reiter et al. [39] performed FEM simu-
lations of water-cooled ICCT (for dening
the size and the position of an internal cool-
ing channel) and carried out experimen-
tal machining of iron-carbon alloy (EN–
GJS–600–3) with a designed tool, with
PCD-coated (poly-crystalline diamond)
cemented tungsten carbide CI, which was
modied with the internal cooling channel.
The researchers came up with the design of
a modied CI with 1.25 mm minimal dis-
tance to the main cutting edge, and after
experimental machining concluded that the
temperature in the cutting area at the cutting
edge decreased considerably below 700 ˚C
(the critical temperature for PCD) with the
use of internal cooling [39].
Continuing their previous research [38],
Li et al. [40] performed numerical analysis
(for mechanical and thermal optimization
of the topological channel), carried out
experimental machining of steel AISI 1045
with the designed water-cooled ICCT (con-
sists of toolholder, modied CI, and adap-
tor), and compared three dierent types of
CI (with the topological IC channels, with
conventional IC channels [38], and without
IC channels), measuring cooling liquid inlet
and outlet line temperatures with two ther-
mocouples. The researchers concluded that,
compared to conventional IC channels, the
topological channel had better heat transfer
ability (under the same uid volume) and
smaller maximum temperature (topological
CI was 16.32 ˚C cooler under the same cut-
ting conditions) could improve mechanical
properties (deformation in the main cut-
ting force direction was 0.03–0.0207 mm
smaller) and was more eective for the
reduction of tool wear [40].
Ravi et al. [1] performed experimen-
tal machining of sandblasted air-quenched
high chrome white cast iron (HCWCI) bars
using CLICCT of their design, which was
cooled with pure water and had cubic boron
nitride (CBN) CI. Researchers concluded
that internal cooling resulted in a reduc-
tion in the machining force (up to 23 %),
ank wear (up to 19 %), and crater wear (up
to 18 %), and that an internal cooling sys-
tem enhanced tool life and brought a lot of
scopes for hard turning process [1].
Wu et al. [41] carried out a numerical
analysis of the tool thermal performance
and tested (by heating with the temperature-
controlled soldering iron and by experi-
mental machining) the designed CLICCT,
which consisted of the toolholder, modied
CI, adaptor module, thermocouples (for
real-time measurement of coolant inlet and
outlet temperatures), and coolant (puried
water) ow rate control system. Among
other things, researchers concluded that
the inlet velocity of the coolant should be
matched with the amount of heat generated
(excessive cooling would only bring energy
waste and increase the cost) [41].
Ozturk et al. [42] manufactured self-
designed closed–loop ICSCT with the
cooling–control system, able to adjust the

83
cooling water ow referring to the CI tip
temperature, for testing the machining pro-
cess of 1040 steel. As a result, ICSCT with
the cooling–control system and self-calibra-
tion based software could estimate the CI
tip temperature and control the coolant ow
rate and inlet temperature; under the same
boundary conditions, the CI tip temperature
could be decreased by as much as 107 ˚C
in the internally cooled condition compared
to the dry condition and made signicant
improvement on the surface of quality com-
pared to dry turning in experiments [42].
The data presented in the research allowed
calculating that the average surface rough-
ness value of ICSCT machined specimen
was 163 % smaller (compared to DM).
Zakaria et al. [44] performed experi-
mental machining of AZ31 magnesium
alloy with the CLICCT of their design,
consisting of a toolholder with uncoated
carbide CI and modied with the cooling
module, which was installed on the top of
the CI and delivered coolant (20 ˚C water)
on the top rake face. The researchers con-
cluded that internal cooling (what authors
dened as “submerged convective cool-
ing”) reduced the cutting temperature up to
15 %, with 6 % cutting force and 12 % feed
force reduction, compared to dry machining
[44].
The results of the reviewed 18 articles,
describing experiments with tool proto-
types, and covering dierent aspects of
machining with the CLICCT, are evaluated
in the discussion section of this paper.

There are several aspects of the 25
overviewed publications that have distinct
approaches (numerical simulations, cool-
ing systems, the design and material of
CT, the conditions and setups of experi-
mental machining, and the main direction
of research) that shall be addressed for the
sake of comparison.

In the scope of 25 selected publica-
tions, 5 articles [6], [29], [36], [38], [43]
cover only the FE and CDF simulations of
CLICCT and in 9 articles [30], [32], [34],
[35], [37], [39]–[42] simulations are only a
part of ICCT research.
The numerical simulations were used
for two main purposes: prediction of tem-
perature distribution and mechanical load
simulations. The goal of temperature dis-
tribution simulations is for the estimation
of the maximal temperature in tool–chip
contact area of ICCT [6, 37] and the com-
parison of estimations of maximal tem-
perature in tool–chip contact area in cases
of DM and IC machining ([29], [30], [32],
[34], [35], [38], [41]–[43]). The aim of
mechanical load simulations is to dene
the wall thickness between the cutting edge
and internal cooling channel [6], [30], [36],
[39], to dene maximal stress and displace-
ment values of the tool (at various boundary
conditions) [38], and to optimize the design
of the internal topological channel [40].

There are several parameters that dene
closed–loop cooling systems: the type of
coolant, coolant inlet temperature, coolant
ow rate and velocity, and coolant ow direc-
tion in CT. The data available in the selected
publications are presented in Table 1.

84
Table 1. CLICCT Cooling System Parameters
Coolant Temperature,
˚C
Flow rate,
l/min
Velocity,
m/s
Coolant ow direction,
inlet / outlet
[28] R123 28 CE side / shank
[45] -10 / 20 shank / shank
[5] ethylene glycol based
coolant 26 0.3 cooling block / cooling block
[30] water 21.3 0.01 0.2 CE side / CE side
[7] water with corrosion
inhibitor 0.3 CE side / shank
[2] 25/75 ethylene glycol and
water solution 0.3 CE side / shank
[46] R141b 32 1.78 CE side / shank
[32] R141b 32 1.78 CE side / shank
[33] water with corrosion
inhibitor 18 8.3 – 33.3 0.8 – 1.6 CE side / CE side
[34] R22 24 CE side / shank
[35] water 18 0.8 – 1.6 CE side / CE side
[37] water 0.08 CE side / CE side
[39] water 1.2 CE side / CE side
[40] water 11 0.001 adaptor module / adaptor module
[1] water 15 Not clear
[41] water 12 0.001 adaptor module / adaptor module
[42] water 22 0.7 – 1.57 CE side / CE side
[44] water 20 0.4 cooling module / cooling module
In Table 1, “CE side” corresponds to the
front part of the CT (closest to the cutting
edge), but “shank” corresponds to the far–
end (to cutting edge) part of toolholder; and
for all refrigerant (phase–changing cool-
ants) cooled systems [28], [32], [34], [46],
the temperature of the coolant corresponds
to its boiling temperature at atmospheric
pressure.
Dierent uids were proposed by
researchers for IC of CT in selected articles:
in 11 articles water (pure, distilled, mixted
with additives) [1], [7], [30], [33], [35],
[37], [39], [41], [42], [44] was proposed as
a cooling uid, in 4 articles – phase chang-
ing coolants [28], [32], [34], [46], and in 2
articles – ethylene glycol solutions [2], [5].
Most researchers chose water as a cool-
ant for CLICCT systems (in 11 articles
out of 18 selected publications describing
experimental machining with ICCT). That
choice can be explained: as the variation
of coolant can have a signicant impact on
heat transfer eciency and water was pre-
ferred as a coolant due to its benecial ther-
mal properties [43].
The cooling performance of ICCT with
the coolant temperatures below 0 ˚C was
studied only in one publication [45]; however,
the type of the coolant was not clearly stated
in the publication. Publication [45] is the
only one, where a comparison of the cool-
ing performance of ICCT, with dierent
coolant temperatures, at the same machin-
ing condition, was carried out.
The comparison of the cooling e-
ciency at changing coolant velocity (and
unchanging machining conditions) was
studied in three articles [33], [35], [42], and
the comparison of the cooling eciency
at changing ow rate of the coolant (and
unchanging machining conditions) was

85
studied in one article [33].
No comparison of the cooling perfor-
mance of the dierent types of coolants
(under the same machining conditions) with
the same design ICCT was found, and no
comparison of the inuence of the coolant
ow direction was carried out.
All 18 selected articles [2], [5], [7],
[28], [30], [32]–[35], [37], [39], [40]–[42],
[44]–[46] resulted in a conclusion that IC
reduced the temperature of CT and that
internal cooling had lower temperatures
in tool–chip contact area, compared with
DM. However, due to dierences in cooling
parameters (type of coolant, coolant inlet
temperature, coolant ow rate and velocity,
and coolant ow direction), the direct com-
parison of numerical values is considered
irrelevant.
The cooling eciency is not solely
based on uid parameters, but cutting
and workpiece material, tool coatings and
engagement conditions, respectively, pro-
cess parameters, which can have a relevant
thermal inuence [43].

The design of proposed CLICCT of
selected articles is based on the modica-
tion of standard CT for turning.
Cooling channels are located in the
plane of contact of CI and the toolholder
[1], [33], [35], [37], [39], [45], in the plane
of contact of CI and the intermediate piece
[2], [5], [7], [30], [40]–[42], [44], or there
is a cooling chamber [28], [32], [34], [46],
which is separated from the CI with the
intermediate piece.
The design data of proposed CLICCT
prototypes (type of CI, modication of CI,
description of the intermediate piece, and its
manufacturing technology) from selected
articles are presented in Table 2.
The cutting edge of the proposed
CLICCT prototypes is formed by the stan-
dard CI in 8 articles [1], [28], [32], [33],
[35], [37], [39], [46] and by the modied
indexable CI in 9 articles [1], [2], [5], [7],
[30], [39]–[41], [45]. In [34], the type of CI
(and if any modications were done) is not
stated.
Table 2. The Design of Prototypes of Proposed CLICCTs
Refer-
ence
Standard indexable cutting
insert (CI) CI Modication Intermediate
piece (IM)
IM manu-
facturing
technology
[28]
TNMA 160408 IC9015
(cemented carbide; TiN, Al2O3
and TiCN triple layer coating)
NO cooper board
[45] SPUN 12XX08 (cemented
carbide) thickness reduced to 1 mm NO -
[5]
2x SNGN 120708 (tungsten car-
bide wiith 6 % cobalt; uncoated
and 8 μm nano-crystalline
diamond coated)
thickness reduced to 1 mm;
diamond coating by hot la-
ment CVD
steel cooling
block
machining with
a micro mill
[30] YD201 SNMG120408 (tungsten
carbide)
electrical discharge wire cut-
ting (EDWC), to reduce thick-
ness to 1.8 mm
support seat
with
[7] SNUN 120408 (6 % cobalt;
tungsten carbide)
electrical discharge machining
(EDM), to fabricate a squared
bottle–cap shape (1 mm wall
thickness)
cooling adaptor
microchannel
machining
with a 5 axis
micro mill

86
Refer-
ence
Standard indexable cutting
insert (CI) CI Modication Intermediate
piece (IM)
IM manu-
facturing
technology
[2] SNUN 120408 (6 % cobalt;
tungsten carbide)
EDM to create a hollow with a
1 mm wall thickness
mild steel cool-
ing adaptor
[46]
TPUN 160308 IC 9054
(cemented carbide; coated with
TiN, TiCN, Al2O3)
NO silver interfac-
ing part
[32] TPUN 160308 IC 20 (uncoated
cemented carbide) NO silver interfac-
ing part
[33] CNMG 190604–IC907 (CVD–
coated carbide) NO NO -
[34] Not specied cooper base
[35] CNMG 190608 IC907 (carbide;
CVD-coated) NO NO -
[37] YT14 31303C (carbide) NO NO -
[39]
TCMW 16T312 (cemented
tungsten carbide; poly-crystal-
line diamond PVC–coated)
EDM to create a cooling chan-
nel NO -
[40] GY3X (3 % cobalt; cemented
carbide)
CI modied; modication type
not specied
carbon steel
adaptor module
(coated with
nickel)
[1] cubic boron nitride (CBN) CI EDM drilling NO -
[41] DNMA 150404 CI modied; modication type
not specied adaptor module
[42] CNMG 190608 (CVD–coated) NO stainless steel
seat
[44] CNMA 120408 (carbide) NO cooling module

The conditions of experimental
machining of selected publications are pre-
sented in Table 3.
Regardless of the grades, steel machin-
ing with CLICCT is researched in 7 articles
[28], [32], [34], [35], [37], [40], [42], alu-
minium – in 2 articles [2], [7], aluminium
alloys – in 2 articles [30], [45]; and 1 article
for each: titanium [5], stainless steel [46],
nickel-based superalloy [33], iron–carbon
alloy [39], high chrome white cast iron [1],
magnesium alloy [44]. In 5 articles [5],
[28], [30], [33], [46] the machined materials
were dened as dicult-to-machine. In one
article [41] material is not specied.
The machined material chemical com-
position is presented in 9 publications [1],
[2], [5], [7], [28], [32], [33], [35], [44] and
machined material mechanical properties
are presented in 4 publications [1], [28],
[32], [46]. The machining setup data are
available in all selected articles (Table 4).
The main directions of the research
are: tool wear research, machined surface
roughness (surface quality) research, and
tool temperature research. The tool wear
research is in the focus of the study in 12
articles [1], [5], [28], [32]–[35], [39], [40],
[44]–[46], surface roughness research – in 6
articles [28], [32], [33], [35], [42], [45], and
tool temperature research – in 13 articles
[5], [7], [30], [32]–[35], [37], [40]–[42],
[44], [46].

87
Table 3. The Conditions of Experimental Machining with CLICCT
Reference
Machined material
Dicult-to-machine mate-
rial
Material chemical compo-
sition present
Material properties present
Machining setup data
Tool wear research
Surface roughness research
Tool temperature research
Compression with DRY
machining
Compression with WET
machining
[28] steel SAE J775 XEV-F X X X X X X X X
[45] aluminium alloy
AlSi7Mg0.3 X X X X X
[5] Titanium 2 CP X X X X X X
[30] aluminium alloy 6061-T6 X X X X
[7] aluminium AA6082-T6 X X X X
[2] aluminium 6082-T6 X X
[46] stainless steel SAE
XEV-F X X X X X X X
[32] steel AISI 1045 XXXXXXXX
[33] nickel–based superalloy
Waspaloy AMS5708 X X X X X X X
[34] steel SAE J775 XEV-F X X X X
[35] steel AISI D2 (DIN
1.2379 X X X X X X
[37] steel AISI 1045 (0.45%
carbon X X X
[39] iron-carbon alloy (EN–
GJS–600–3 X X X X
[40] steel AISI 1045 X X X X
[1] high chrome white cast
iron (HCWCI) X X X X X
[41] X X X
[42] steel AISI 1040 X X X X
[44] magnesium alloy AZ31 X X X X X
Three articles [32], [33], [35] cover
three directions of research, 8 articles [5],
[28], [34], [40], [42], [44]–[46] cover two
directions of research, and 6 articles cover
one direction of research [1], [7], [30], [37],
[39], [41]. In article [2], the research is aim-
ing to identify and quantify the eect of the
cutting parameters on the eectiveness of
the internal cooling system.
In 17 articles [1], [5], [7], [28], [30],
[32]–[35], [37], [39]–[42], [44]–[46], the
performance of ICCT is compared with DM
(at the same machining setup). In 5 articles
[28], [32], [39], [45], [46], in addition to
DM comparison, the performance of ICCT
is compared with conventional wet or ood
cooling.
Because 17 selected research [1], [5],
[7], [28], [30], [32]–[35], [37], [39]–[42],
[44]–[46] have results for machining with
IC and DM, and comparison of those
results, there is enough experimentally
achieved data to evaluate tool wear, surface
roughness, and cooling eectiveness (tool

88
temperature reduction) for both machining
conditions.
The comparison of the numerical values
of the results (the tool wear values, speci-
men surface roughness values, the values of
temperature reduction in the tool–chip con-
tact area due to IC), due to dierences in
the machining conditions (machining mate-
rial, machining setup) and the directions
of research, as well as insucient or not
presented information (machined material
composition and properties), is considered
irrelevant.
Table 4. The Setups of Experimental Machining with CLICCT
Cutting speed VC,
m/min
Feed rate f,
mm/rev
Depth of cut aP,
mm
Specimen diam-
eter D,
mm
Specimen
length L,
mm
[28] 140 0.43 0.50 50 300
[45] 1000 0.15 0.30
[5] 80 0.20 1.00 60 150
[7] 250 / 300 / 350 0.10 / 0.15 / 0.20 0.20 / 0.35 / 0.50 65 450
[2] 250 / 300 / 350 0.10 / 0.15 / 0.20 0.20 / 0.35 / 0.50 65 450
[46] 80 / 100 0.20 / 0.40 0.50
[32] 80 / 100 0.20 / 0.40 1.0 50 250
[33] 45 / 65 / 95 0.10 0.50 38 300
[34] 100 / 130 / 170 0.10 1.0 50 155
[35] 80 / 113 / 170 0.08 0.50 45 300
[39] 180 0.07 1.2
[1] 55 / 88 / 136 0.096 / 0.124 / 0.179 0.1 / 0.2 / 0.3
[41] 0.16 1.0
[44] 120 / 180 / 240 0.20 1.0 30 100
Cutting speed VC,
rpm
Feed rate f,
mm/rev
Depth of cut aP,
mm
Specimen diam-
eter D,
mm
Specimen
length L,
mm
[37] 410 0.10 1.0 60
[40] 320 0.16 1.0 100
[42] 500 / 710 / 1000 0.08 / 0.11 / 0.14 1.0 / 2.0 / 3.0 30 30
Cutting speed VC,
rpm
Feed rate f,
mm/min
Depth of cut aP,
mm
Specimen diam-
eter D,
mm
Specimen
length L,
mm
[30] 220 / 430 / 670 /
1525 45 1.00 50 500

The tool wear of ICCT and its com-
parison with the wear of dry-machining CT,
in the scope of selected articles, consist of
ank wear [1], [5], [28], [32]–[35], [39]–

89
[40], [44]–[46], nose wear [28], crater wear
[1], [32], [40], [46], built-up edge [44], [45],
built-up layer and tool chipping wear [44].
In 12 studies [1], [5], [28], [32]–[35],
[39]–[40], [44]–[46] authors concluded that
IC reduced ank wear of ICCT (compared
with DM). The nose wear of an ICCT is
smaller than the nose wear of dry-machin-
ing CT at the same machining setup [28].
The build-up edge [44] and build-up layer
[44] rates are also lower, compared with
dry-machining CT at the same machining
setup.
The results of crater wear evaluation for
ICCT and dry-machining CT, in the scope
of selected articles, are divided: ICCT cra-
ter wear is smaller compared to DM [1],
[40], and ICCT crater wear, depending on
machining setup, is smaller, approximately
equal or bigger, compared to DM [32], [46].
The dierence in the crater wear related
results might be explained by the dierence
in machined material and machining setup.
The authors of 4 articles [5], [28],
[33], [46] refer to ISO 3685-1993 standard
(Tool–life testing with single–point turning
tools), for the guidance for veriable tool
wear evaluation method.
The surface roughness research was
presented in 6 articles: the authors of 5 arti-
cles [5], [28], [33], [42], [45] concluded that
the surface roughness of the machined with
ICCT specimen is smaller (surface quality
is better), compared with the dry-machined
specimen; and the authors of article [32]
concluded that the surface roughness of the
machined with ICCT specimen, depending
on machining setup, was smaller, approxi-
mately equal or bigger, compared to DM.
The authors of 13 publications [5], [7],
[30], [32]–[35], [37], [40]–[42], [44], [46],
where tool temperature research was carried
out, concluded that the temperature in tool–
chip contact area of ICCT during machin-
ing with IC was lower that the temperature
in tool–chip contact area of CT during DM.

The number of scientic articles focus-
ing on internally cooled cutting tools
increased from 6 in 2000 to 62 in 2022.
Experimental turning with prototypes
of closed-loop internally cooled cutting
tools proved that:
1. closed-loop internally cooled cutting
tools can be used for turning various
materials including dicult-to-machine
materials: steel and stainless steel, alu-
minium and aluminium alloys, iron–
carbon alloy, high chrome white cast
iron, titanium, nickel-based superalloy,
magnesium alloy;
2. closed-loop internally cooled cutting
tools for turning have smaller tool wear
and a longer lifetime, due to lower tem-
perature in tool–chip contact area, com-
pared to dry-machining;
3. closed-loop internally cooled cutting
tools for turning provide a better sur-
face quality (smaller surface roughness)
of the machined parts, compared to dry-
machining;
4. turning with closed-loop internally
cooled cutting tools shares the same
advantages as dry turning: no coolant
contamination, no coolant consump-
tion, it is environmentally friendly, and
has fewer health hazards.
More specic research on a design for
the development of a sustainable CLICCT
is still a eld for future research.

90
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