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Development of a cyclic liquid nitrogen injection system and its application to minimum quantity lubrication milling of the Ti-6Al-4V alloy

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Abstract

The Ti-6Al-4V alloy represents a large portion of the material used in medical and aerospace applications due to its excellent properties. Its machining requires unique conditions, and new machining proposals are presented every day. This work describes a condition of sustainable manufacturing, minimizing the waste of cutting fluid by a cycle lubrication approach. The system developed has an electronic circuit for controlling the flow of liquid nitrogen under pressure applied to a commercial valve. A 23 factorial planning design following the recommendations of the cutting insert manufacturer was carried out; the machining tests were performed under the conditions stipulated. Roughness studies were carried out for different cooling strategies as well as the insert flank wear. The cycle system showed that liquid nitrogen is saved and there are lower Sa and Sz roughness values compared with machining without lubrication and classical nitrogen injection. Simulations using the computational fluid dynamics approach were implemented. The behavior of a drop of liquid nitrogen under the action of gravity and its behavior in the bulkhead were simulated. The specified tool height when machining allows the adequate lubrication of the tool.

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Abbreviations

a p :

Depth of cut (DOC) [mm]

f :

Feed rate [mm/rev]

K :

Kelvin [K]

S a :

Arithmetic average height of the surface [μm]

S ku :

Kurtosis of height distribution [dimensionless]

S sk :

Skewness of height distribution [dimensionless]

S z :

Maximum height [μm]

V b :

Flank wear [mm]

v c :

Cutting speed [m/min]

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Acknowledgements

The Instituto Maua de Tecnologia of Sao Caetano do Sul and Instituto SENAI of Sao Paulo are acknowledged for making their laboratories available for the test’s executions.

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Authors and Affiliations

  1. Department of Mechatronics and Mechanical Systems Engineering, Polytechnic School of the University of Sao Paulo, Av. Prof. Mello Moraes, 2231, Cidade Universitária, Sao Paulo, SP, 05508-900, Brazil

    Nelson W. Paschoalinoto & Gilmar F. Batalha

  2. Department of Production Engineering and Mechanical Engineering, University Center of the Mauá Institute of Technology (IMT), Campus São Caetano do Sul, Praça Mauá 1, Sao Caetano do Sul, SP, 09580 900, Brazil

    Nelson W. Paschoalinoto & Ed C. Bordinassi

  3. Faculty of Mechatronic Technology, National Service for Industrial Training (SENAI-SP), Rua Santo André, 680 – Boa Vista, São Caetano do Sul, SP, 09572-300, Brazil

    Paulo S. Ladivez & Aderval F. de Lima Filho

  4. Department of Mechanical Engineering, University Center of Educational Foundation of Ignatius (FEI), Av. Humberto de Alencar Castelo Branco, 3972, Bairro Assunçao, São Bernardo do Campo, SP, 09850-901, Brazil

    Ed C. Bordinassi

  5. Institute for Innovation in Advanced Manufacturing and Microfabrication, National Service for Industrial Training (SENAI-SP), Rua Bento Branco de Andrade Filho, 379, Santo Amaro, São Paulo, SP, 04757-000, Brazil

    Gleicy de L. X. Ribeiro

Authors
  1. Nelson W. Paschoalinoto
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  2. Gilmar F. Batalha
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  3. Paulo S. Ladivez
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  5. Aderval F. de Lima Filho
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Contributions

Nelson W. Paschoalinoto: conceptualization, methodology, writing. Gilmar F. Batalha: supervision review, validation. Paulo S. Ladivez: research, validation. Ed Claudio Bordinassi: writing, resources and review. Aderval F de L. Filho: investigation, data curation, visualization. Gleicy de L. X. Ribeiro: conceptualization, investigation, visualization.

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Correspondence to Nelson W. Paschoalinoto.

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Paschoalinoto, N.W., Batalha, G.F., Ladivez, P.S. et al. Development of a cyclic liquid nitrogen injection system and its application to minimum quantity lubrication milling of the Ti-6Al-4V alloy. Int J Adv Manuf Technol 118, 1529–1552 (2022). https://doi.org/10.1007/s00170-021-07994-4

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