Enhanced Cooling Performance in Cutting Tools Using TPMS-Integrated Toolholders: A CFD-Based Thermal-Fluidic Study

The efficient thermal management of cutting tools is critical for ensuring dimensional accuracy, surface integrity, and tool longevity, especially in the high-speed dry machining process. However, conventional cooling methods often fall short in reaching the heat-intensive zones near the cutting inserts. This study proposes a novel internal cooling strategy that integrates triply periodic minimal surface (TPMS) structures into the toolholder, aiming to enhance localized heat removal from the cutting region. The thermal-fluidic behaviors of four TPMS topologies (Gyroid, Diamond, I-WP, and Fischer–Koch S) were systematically analyzed under varying coolant velocities using computational fluid dynamics (CFD). Several key performance indicators, including the convective heat transfer coefficient, Nusselt number, friction factor, and thermal resistance, were evaluated. The Diamond and Gyroid structures exhibited the most favorable balance between heat transfer enhancement and pressure loss. The experimental validation confirmed the CFD prediction accuracy. The results establish a new design paradigm for integrating TPMS structures into toolholders, offering a promising solution for efficient, compact, and sustainable cooling in advanced cutting applications.