The Relationship between Tool Coatings and Process Parameters on Cutting Forces and Wear in High-Speed Machining

This paper provides a comprehensive analysis of cutting force dynamics in High-Speed Machining (HSM), a critical factor for ensuring structural integrity and productivity in advanced manufacturing. The study synthesizes the role of piezoelectric dynamometry and the Finite Element Method (FEM) in predicting and monitoring force vectors during the processing of difficult-to-cut alloys, specifically Inconel 718 and Ti–6Al–4V. A critical investigation is conducted into how tool edge micro-geometry and nanostructured coatings (e.g., AlTiN, ZrN) manipulate the thermomechanical interface, leveraging the thermal softening effect to counteract high work-hardening rates. Furthermore, the research evaluates the impact of lubrication strategies, such as Minimum Quantity Cooling Lubrication (MQCL), and tool-path kinematics, including ramp, helical, and plunge entries, on the stability of cutting forces and sub-surface integrity. To bridge the gap between laboratory findings and industrial scalability, a strengths, weaknesses, opportunities, and threats (SWOT) analysis is employed, identifying the strengths of adiabatic shearing and the threats of dynamic instability. The findings conclude that the synergy between precise parameter selection and real-time force feedback is essential for mitigating the “size effect” and preventing catastrophic tool failure. This review serves as a technological roadmap for implementing data-driven HSM processes, emphasizing the transition toward sustainable, zero-defect manufacturing in the aerospace and mold-making sectors. Unlike previous reviews that focus solely on material properties, this study establishes a novel integrated framework that correlates tool coating synergistic effects with dynamic process parameters specifically for difficult-to-cut alloys. The scientific novelty lies in the systematic identification of the ‘coating-parameter-wear’ nexus, providing a predictive perspective for optimizing high-speed machining through a combined SWOT-FEM analytical approach.