Nowadays, the need for not only technically but also environmentally efficient machining processes is increasing. In this context, the reduction of oil emulsion type coolants used during machining of aeronautical engine components supposes a great challenge. In this paper, a novel approach based on the design, optimization and validation of a nozzle adaptor combining cryogenic technology and minimum quantity lubrication systems is proposed. The proposed work also deals with the aim of obtaining a cost-effective process. Thus, CO2 flow and velocity was optimized in this line. Theoretically-based analysis were performed and compared with computational fluid dynamics (CFD) simulations and with real experimental tests as well. Once optimizing these key factors, two nozzle adaptors were designed and simulated by CFD. Different geometries were tested looking for the most efficient design. Finally, to obtain a feasible industrial product, the developed nozzle was tested as a CryoMQL demonstrator comparing with other lubricoolant techniques during milling Inconel 718. Results show a successful balance between technical and environmental issues using this technology when milling aeronautical alloys.
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Pereira, O., Rodríguez, A., Barreiro, J. et al. Nozzle design for combined use of MQL and cryogenic gas in machining. Int. J. of Precis. Eng. and Manuf.-Green Tech. 4, 87–95 (2017). https://doi.org/10.1007/s40684-017-0012-3