Projects per year
Abstract
Manufacturing and, in particular, machining are responsible for a significant portion of global industrial energy consumption (25%). Previous research has shown that precise selection of cutting parameters can improve the energy consumption of machining processes. Cryogenic machining has attracted significant attention for improving the machinability of difficult-to-machine materials while also eliminating the environmental and health issues associated with the use of cutting fluids. Despite the advantages, there is a considerable research gap in cryogenic milling operations. This article investigates the effect of cryogenic cooling using liquid nitrogen in end milling of Ti-6Al-4V. A robust and rigorous methodology was developed and a series of machining experiments were conducted using a combination of cutting parameters repeated at dry, flood and cryogenic cooling environments. The investigations indicated that cryogenic cooling considerably reduce tool wear when compared to dry and flood cooling while allowing for using higher cutting speeds. The cutting tool used for cryogenic machining at 200 m/min cutting speed, 0.03 mm/tooth feed rate and 5 mm depth of cut showed minimum flank wear. Furthermore, the investigations demonstrated that using the machine’s coolant pump in flood cooling resulted in higher power and energy consumption than dry and cryogenic cooling. This article clearly shows that higher material removal rates are required in order to minimise specific machining energy. Therefore, since cutting speed is limited in dry machining, cryogenic machining is the most favourable as higher cutting speeds can be used. Using cryogenic machining at 200 m/min cutting speed resulted in an 88% reduction in energy consumption of the machine tool as compared to flood cooling at 30 m/min while minimum tool wear (10 µm) was detected. This clearly demonstrates the significant capabilities of cryogenic machining when compared with more conventional machining approaches.
Original language | English |
---|---|
Pages (from-to) | 1690-1706 |
Number of pages | 17 |
Journal | Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture |
Volume | 232 |
Issue number | 10 |
Early online date | 26 Sept 2016 |
DOIs | |
Publication status | Published - 1 Aug 2018 |
Keywords
- Cryogenic machining
- Tool wear
- Computer numerical control (CNC)
- Milling
- end milling
- Power consumption
- Energy consumption
Fingerprint
Dive into the research topics of 'Energy Conscious Cryogenic Machining of Ti-6Al-4V Titanium Alloy'. Together they form a unique fingerprint.Projects
- 1 Finished
-
Cryogenic Machining of Hard Metal Alloys (CRYOSIS)
Newman, S., Dhokia, V. & Nassehi, A.
Engineering and Physical Sciences Research Council
1/10/12 → 30/09/15
Project: Research council
Profiles
-
Vimal Dhokia
- Department of Mechanical Engineering - Deputy Head of Department
- Made Smarter Innovation: Centre for People-Led Digitalisation
- Centre for Digital, Manufacturing & Design (dMaDe)
- EPSRC Centre for Doctoral Training in Advanced Automotive Propulsion Systems (AAPS CDT)
- Institute for Advanced Automotive Propulsion Systems (IAAPS)
Person: Research & Teaching, Core staff, Affiliate staff
-
Alborz Shokrani Chaharsooghi
- Department of Mechanical Engineering - Reader
- Made Smarter Innovation: Centre for People-Led Digitalisation
- Centre for Digital, Manufacturing & Design (dMaDe)
Person: Research & Teaching, Core staff