Manufacturing high precision and high performance parts in aerospace, automotive and medical industries often requires machining of difficult-to-cut materials such as titanium, nickel and hardened alloyed steel alloys. Low productivity and environmental damage are major problems in cutting these materials, which vitally require optimized cooling strategies. High-pressure cutting fluid supply (HP CF) and cryogenic cooling lubrication (CRYO CL) are two of the most effective cooling lubrication approaches to increase tool life, productivity and avoid scrap production. The scientific and knowledge-based application of HP CF and CRYO CL had a pivotal role in improving the machining of difficult-to-cut materials, specifically in milling processes. In this context, the quantification of the cooling and lubrication effect of HP CF and CRYO CL is essential in order to adapt to the fluctuating heat generation at the cutting zone. The novel concept of a soft sensor for the quantification of the cooling and lubrication effect in the milling process is presented in this paper. This soft sensor integrates force measurements and transient temperature data from the process with the help of a mechanical model as well as an inverse temperature model. These models elevate the measured force and temperature signals to heat flows and power in the thermodynamic domain enabling an energy balancing in the real milling application. A telemetry system was used to measure the transient temperature in the milling tool with embedded thermocouples when milling 42CrMo4 and Ti-6Al-4 V in αβ and β conditions. This way the separated cooling versus lubrication effect of high-pressure cutting fluid supply and a single channel cryogenic cooling lubrication based on carbon dioxide (CO₂) and oil is investigated and compared with dry machining at various cutting parameters and proceeding tool wear.

在航空航天、汽车和医疗行业制造高精度和高性能零件通常需要加工难以切削的材料，例如钛、镍和硬化合金钢合金。低生产率和环境破坏是切割这些材料的主要问题，这迫切需要优化的冷却策略。高压切削液供应 (HP CF) 和低温冷却润滑 (CRYO CL) 是两种最有效的冷却润滑方法，可延长刀具寿命、生产率并避免产生废料。HP CF 和 CRYO CL 的科学和知识应用在改进难切削材料的加工方面发挥了关键作用，特别是在铣削过程中。在这种情况下，量化 HP CF 和 CRYO CL 的冷却和润滑效果对于适应切割区产生的波动热量至关重要。本文介绍了用于量化铣削过程中冷却和润滑效果的软传感器的新概念。这种软传感器在机械模型和逆温度模型的帮助下集成了来自过程的力测量值和瞬态温度数据。这些模型将测得的力和温度信号提升为热力学域中的热流和功率，从而在实际铣削应用中实现能量平衡。在 αβ 和 β 条件下铣削 42CrMo4 和 Ti-6Al-4 V 时，使用遥测系统测量带有嵌入式热电偶的铣削刀具的瞬态温度。₂ ) 和油在不同的切削参数和进行刀具磨损下进行了研究并与干切削进行了比较。