Effect of Tool Cavity Conditions on Damping, Chatter Mitigation, and Surface Quality in Internally Cooled Milling Tools

Abstract

Chatter is a critical factor limiting productivity and efficiency in machining processes. Cutting tools significantly impact chatter stability, as they often serve as the most flexible component. The influence of cutting tools on chatter varies depending on their design and cooling mechanisms. Internally cooled cutting tools, commonly used in industrial applications, have the potential to exhibit distinct damping characteristics due to the presence of internal cavities, differentiating them from conventional solid tools. This study explores the effects of internally cooled milling cutting comparing an empty cavity cutting tool with a tool filled with viscous fluid. The primary objective is to evaluate how these conditions influence the damping of the machining system and their subsequent impact on surface quality, a key outcome sensitive to chatter. Surface topography and roughness measurements were taken after the experiments to assess changes in surface quality. The findings offer valuable insights into the role of internal cooling and fluid properties in not only chatter but also vibration suppressions in milling operations, highlighting their potential to enhance machining performance. © 2025 The Author(s).