Investigation of the surface integrity when cryogenic milling of Ti-6Al-4V using a sub-zero metalworking fluid

Gutzeit, Kevin; Bulun, Georgis; Stelzer, Gerhard; Kirsch, Benjamin; Seewig, Jörg; Aurich, Jan C.

doi:10.1016/j.procir.2022.03.010

Cited by 10 publications

(4 citation statements)

References 16 publications

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“…In previous works, the application of sub-zero cooling strategies resulted in less tool wear [39] and an optimized surface integrity [40,41] when turning Ti-6Al-4V. While milling Ti-6Al-4V, a favourable thermo-mechanical load has also been observed by us, which resulted in a better surface quality compared to a cryogenic cooling strategy [42].…”

Section: Introductionmentioning

confidence: 51%

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Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Gutzeit

Bulun²,

Stelzer³

et al. 2023

Preprint

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Due to an excellent ratio of high strength and low density, Ti-6Al-4V is suitable for many industrial applications, especially in the aerospace industry. However, Ti-6Al-4V is also characterized as a hard to-cut material. This is mainly attributed to its very low thermal conductivity and high chemical reactivity, especially at elevated temperatures. Machining Ti-6Al-4V leads to high cutting temperatures and thermal loads of the tools within the cutting zone. This enhances a rapidly progressing, thermo-chemical induced tool wear reducing tool life and productivity. To enhance the cutting performance, suitable cooling strategies are a necessity to reduce the thermal load and hence to improve the machinability of Ti-6Al-4V. A novel, highly efficient cooling approach is to apply sub-zero metalworking fluids (MWF) at liquid state but at supply temperatures well below 0°C. These sub-zero MWF inhibit high cooling effects due to their low supply temperature in superposition with a beneficial wetting behavior. Within this paper, the application of a sub-zero cooling strategy is investigated and compared to a cryogenic CO2 cooling. The performance of both cooling strategies is analyzed when milling Ti-6Al-4V by systematically varying the cutting parameters and the milling strategy. The milling process is described on the basis of the occurring forces, the resulting wear and the surface quality. The results show that the sub-zero cooling outperforms the cryogenic CO2 cooling, especially at elevated cutting parameters and unfavorable cutting conditions. Less tool wear and an overall better surface quality are observed for sub-zero milling when being compared to cryogenic milling.

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Section: Introductionmentioning

confidence: 51%

“…By now, the application of sub-zero MWF for milling operations has so far only been investigated at comparably low cutting speeds (vc = 50 m/min) [42]. However, the cutting parameters chosen have a decisive impact on the performance of the cooling strategy and the respective cutting process.…”

Section: Introductionmentioning

confidence: 99%

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Gutzeit

Bulun²,

Stelzer³

et al. 2023

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…When turning Ti-6Al-4 V while using a sub-zero MWF, a favorable thermo-mechanical load was observed, resulting from the enhanced heat transfer in superposition with an improved lubrication. Consequently, a better surface quality and less tool wear was observed in comparison to cryogenic cooling approaches [21,22]. First studies in sub-zero milling have also shown the potential for better surface integrity, less adhesion at the cutting edges as well as longer tool life compared to dry machining or the use of cryogenic cooling approaches [21,22].…”

Section: List Of Symbolsmentioning

confidence: 99%

“…Consequently, a better surface quality and less tool wear was observed in comparison to cryogenic cooling approaches [21,22]. First studies in sub-zero milling have also shown the potential for better surface integrity, less adhesion at the cutting edges as well as longer tool life compared to dry machining or the use of cryogenic cooling approaches [21,22]. A systematic configuration of the sub-zero MWF application in terms of supply temperature, flow rate and nozzle outlet velocity was not yet conducted for milling, although it offers a high potential for increasing the efficiency of this novel cooling strategy.…”

Section: List Of Symbolsmentioning

confidence: 99%

Optimization of the cooling strategy during cryogenic milling of Ti-6Al-4 V when applying a sub-zero metalworking fluid

Gutzeit¹,

Berndt²,

Schulz

et al. 2022

Prod. Eng. Res. Devel.

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Due to an excellent ratio of high strength to low density, as well as a strong corrosion resistance, the titanium alloy Ti-6Al-4 V is widely used in industrial applications. However, Ti-6Al-4 V is also a difficult-to-cut material because of its low thermal conductivity and high chemical reactivity, especially at elevated temperatures. As a result, machining Ti-6Al-4 V is characterized by high thermal loads and a rapidly progressing thermo-chemical induced tool wear. An adequate cooling strategy is essential to reduce the thermal load and therefore tool wear. Sub-zero metalworking fluids (MWF) which are applied at liquid state but at supply temperatures below the ambient temperature, offer great potential to significantly reduce the thermal load when machining Ti-6Al-4 V. Within the presented research, systematically varied sub-zero cooling strategies are applied when milling Ti-6Al-4 V. The influences of the supply temperature, as well as the volume flow and the outlet velocity are investigated aiming at a reduction of the thermal loads that occur during milling. The milling experiments were recorded using high-speed cameras in order to characterize the impact of the cooling strategies and resolve the behavior of the MWF. Additionally, the novel sub-zero cooling approach is compared to a cryogenic CO2 cooling strategy. The results show that the optimized sub-zero cooling strategy led to a sufficient reduction of the thermal loads and does outperform the cryogenic cooling even at elevated CO2 mass flows.

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Creating Surface Morphologies by Cryogenic Machining

Kirsch,

Aurich,

Gutzeit

et al. 2023

Springer Series in Advanced Manufacturing

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Investigation of the surface integrity when cryogenic milling of Ti-6Al-4V using a sub-zero metalworking fluid

Cited by 10 publications

References 16 publications

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Optimization of the cooling strategy during cryogenic milling of Ti-6Al-4 V when applying a sub-zero metalworking fluid

Creating Surface Morphologies by Cryogenic Machining

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