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Tool wear in Ti-6Al-4V alloy turning under oils on water cooling comparing with cryogenic air mixed with minimal quantity lubrication

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Abstract

Wet cutting is the most common cooling method used during the cutting of titanium alloys. However, this method is associated with high costs, pollution, and hazards to operators. Minimal quantity lubrication (MQL) is an effective environmentally friendly cooling method, but is not suitable for difficult-to-machine materials because of its low heat transfer capacity. Using cryogenic air mixed with MQL (CAMQL) for cooling has better heat transfer, but high equipment costs and noise pollution limit its industrial application. This paper proposes the use of oils on water (OoW) as a cooling method for the turning of Ti-6Al-4V alloy and aims at exploring the effect of OoW cooling. Both external oils on water (EOoW) and internal oils on water (IOoW) methods are considered. The effects of EOoW spraying location and the amount of water required for IOoW are compared with respect to chip morphology, cutting temperatures, cutting forces, surface roughness, and tool wear. The use of CAMQL at different air temperatures is compared with wet and dry cutting. The results show that the chips created by OoW and CAMQL are continuous spirals. Compared with CAMQL, use of IOoW cooling with an appropriate amount of water or EOoW cooling from a proper location yields lower surface roughness and slower flank wear rate, and bare areas on the cutting tool substrate were absent because of better lubrication. The properties of the lubricants have an influence on IOoW and CAMQL, but not on EOoW. A suitable cutting tool coating should be selected to ensure the best cutting performance under these cooling methods.

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Authors and Affiliations

  1. Guangdong University of Technology, Guangzhou, 510006, China

    Haisheng Lin, Chengyong Wang, Yaohui Yuan, Zhihua Chen & Qimin Wang

  2. DG Armorine Energy-Efficient and Eco-Friendly Tech Corp., Dongguang, 523039, China

    Weiqiang Xiong

Authors
  1. Haisheng Lin
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  2. Chengyong Wang
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  3. Yaohui Yuan
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  4. Zhihua Chen
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  5. Qimin Wang
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  6. Weiqiang Xiong
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Correspondence to Chengyong Wang.

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Lin, H., Wang, C., Yuan, Y. et al. Tool wear in Ti-6Al-4V alloy turning under oils on water cooling comparing with cryogenic air mixed with minimal quantity lubrication. Int J Adv Manuf Technol 81, 87–101 (2015). https://doi.org/10.1007/s00170-015-7062-x

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  • DOI: https://doi.org/10.1007/s00170-015-7062-x

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