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Pre-cooling Intensity Effects on Cooling Efficiency in Cryogenic Turning

  • Research Article - Mechanical Engineering
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Abstract

The requirement for utilization of safe lubricants is rising in all parts of the industry due to human and environmental concerns. Therefore, complete omission or replacement of the mineral-based cutting fluids by safer ones is deemed to be very important in today’s machining operations. In the present study, the effect of pre-cooling in cryogenic machining using liquid nitrogen was compared with dry machining. Tool temperature, workpiece surface quality and tool wear were studied as the output response parameters. The results showed that the tool temperature had no sensitivity to the cutting parameters when liquid nitrogen was employed. However, in dry machining as the cutting parameters (i.e., cutting speed and feed rate) increased, the cutting temperature rose. Pre-cooling by liquid nitrogen led to reduction of the tool temperature by 73–86% compared with the dry method. Also, surface quality in terms of defective zones such as adhered materials, removed regions, and scratch marks was evaluated. It was observed that many defects were formed on the workpiece surface in dry machining, whereas it was completely defect free in cryogenic machining. Concerning the tool wear, the SEM images of tool rake face showed that the tool wear under the mechanisms of adhesion and breakage was observed in a vast area of the tool surface in dry machining, enhancing the creation of defects on the workpiece surface.

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Abbreviations

BUE:

Built-up edge

BUL:

Built-up layer

EDX:

Energy-dispersive X-ray spectroscopy

V f :

Chip speed on tool rake face

a w :

Chip width

F c :

Cutting force

r c :

Cutting ratio

V c :

Cutting speed

ρ :

Density of workpiece

f :

Feed rate

β :

Friction angle

µ :

Friction coefficient

F f :

Friction force

P s :

Generated heat rate in primary deformation zone

P f :

Generated heat rate in secondary deformation zone

Φ c :

Heat transfer rate to the chip

Φ t :

Heat transfer rate to the tool

Φ w :

Heat transfer rate to the workpiece

θ f :

Increased average temperature due to secondary deformation

θ s :

Mean temperature of materials when crossing the primary deformation zone

Γ :

Percentile of transferred heat to the workpiece

P m :

Power consumption in cutting process

α :

Rake angle

C :

Special heat capacity of the workpiece

a c :

Uncut chip thickness

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Authors and Affiliations

  1. Department of Mechanical Engineering, Amirkabir University of Technology, Tehran, Iran

    Seyed Hasan Musavi

  2. Sustainable Manufacturing Systems Research Laboratory (SMSRL), School of Mechanical Engineering, Iran University of Science and Technology, Tehran, Iran

    Behnam Davoodi

  3. Department of Mechanical, Automotive, and Materials Engineering, University of Windsor, Windsor, Canada

    Behzad Eskandari

Authors
  1. Seyed Hasan Musavi
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  2. Behnam Davoodi
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  3. Behzad Eskandari
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Correspondence to Behnam Davoodi.

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Musavi, S.H., Davoodi, B. & Eskandari, B. Pre-cooling Intensity Effects on Cooling Efficiency in Cryogenic Turning. Arab J Sci Eng 44, 10389–10396 (2019). https://doi.org/10.1007/s13369-019-04056-6

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  • DOI: https://doi.org/10.1007/s13369-019-04056-6

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