FE Simulation of Cryogenic Assisted Machining of Ti Alloy (Ti6AI4V)

Abstract

Titanium alloys are well-known material because of the excellent mechanical/chemical properties, corrosion resistance and light weight. These alloys are widely used in the high performance applications such as; aerospace, aviation, bio-implants, turbine blades etc. Machining is commonly used to create products out of Ti alloys. Despite of good material properties, Ti alloys have low thermal conductivity, poor machinability, burr formation, high machining temperature, tool wear and poor machinability. The tool wear and high machining temperature can be controlled through coolant. Cryogenic fluid (liquid nitrogen) is a common material used as coolant in various machining process. The current work is focused on the modeling of cryogenic machining on titanium alloy (Ti6Al4V). Dry machining and cryogenic machining processes are modeled for the chip formation and cutting forces in 2D. Experimental works have been performed to validate the model based on the cutting forces and chip morphology. It is showed that the model is capturing the process, evident by the cutting forces and the chip morphology. The error in prediction is limited to 18%. Model showed that the cutting forces are increasing in cryogenic machining due to the increased strength of the workpiece at low temperature. Chip formation is well captured by the current model. Shear band width have been captured in dry machining. Chip curling has been captured at dry and cryogenic machining. It is expected that the model can further useful in the selection of cryogenic process parameter, such as, flow rate, application techniques etc.

Experimental investigation of the effects of cryogenic cooling on tool life in Ti6Al4V milling

“…In order to improve the knowledge on cryogenics in turning, a few studies focused on the finite element (FE) modeling were carried out [15][16][17]. Although many works on cryogenic turning have been developed, the literature is rather poor for what concerns the use of cryogenic in milling, especially if the performance assessment with respect to the industrial reference solutions (wet machining) is of interest.…”

Investigation of High-Speed Cryogenic Machining Based on Finite Element Approach

“…An effective method to reduce machining temperatures is refrigeration cooling in which the liquid nitrogen is used as the coolant, usually. Various researchers by using the cryogenic method have examined the machining process in theory (Bajpai et al 2015), Rana et al (2016), Schoop et al (2016), Umbrello et al (2016)), and experiment (Biermann et al (2015), Dinesh et al (2016), Giasin et al (2016), Gupta et al (2016)). When cryogenic science is discussed, it is implied the use of refrigeration of fluids with lower temperatures than -150 .…”