Research Papers

Prediction of Tool-Chip Interface Temperature in Cryogenic Machining of Ti–6Al–4V: Analytical Modeling and Sensitivity Analysis

[+] Author and Article Information
Sinan Kesriklioglu

Department of Mechanical Engineering,
University of Wisconsin,
1513 University Avenue, ME 1031,
Madison, WI 53706
e-mail: kesriklioglu@wisc.edu

Frank E. Pfefferkorn

Department of Mechanical Engineering,
University of Wisconsin,
1513 University Avenue, ME 1031,
Madison, WI 53706
e-mail: frank.pfefferkorn@wisc.edu

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS. Manuscript received March 27, 2018; final manuscript received July 3, 2018; published online September 17, 2018. Assoc. Editor: Aaron P. Wemhoff.

J. Thermal Sci. Eng. Appl 11(1), 011003 (Sep 17, 2018) (10 pages) Paper No: TSEA-18-1158; doi: 10.1115/1.4040990 History: Received March 27, 2018; Revised July 03, 2018

The goal of this work is to predict the tool-chip interface temperature during cryogenic machining and determine the effectiveness of this cooling strategy. Knowledge of the tool-chip interface temperature is needed to conduct process planning: choosing a tool cooling geometry, cutting speed, and cryogen flow rate as well as predicting tool life and achievable material removal rate. A detailed explanation of the analytical heat transfer model is presented, which is a modified form of Loewen and Shaw's orthogonal cutting model, where a thermal resistance network is applied to represent the heat transfer mechanisms in, and out of, the cutting tool. An in-depth discussion of the temperature rise at the tool-chip interface during orthogonal machining of titanium alloy Ti–6Al–4V is presented. The effect of cutting speed, cryogen flow rate and quality, and cooling strategy are explored. The model is used to compare the effect of internal cryogenic cooling with external flood cooling using a water-based metalworking fluid or liquid nitrogen. A sensitivity analysis of the model is conducted and ranks the relative importance of various design parameters. The thermal conductivity of the cutting insert has the greatest influence on the predicted interface temperature. The low boiling temperature and phase change are what make internal cooling of a cutting insert with liquid nitrogen effective at reducing the tool-chip interface temperature. If the heat flowing into the tool, from the tool-chip interface, does not exceed the available latent heat in the cryogen, then this method is more effective than external flood cooling.

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Fig. 1

Dual nozzle system to externally supply LN2 to the cutting zone [9]

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Fig. 2

Modified inserts for (a) external (b) internal cooling2

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Fig. 3

Heat source and heat partitioning through the tool-chip interface

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Fig. 4

Thermal resistance network for external flood cooling

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Fig. 5

Mirroring the insert to obtain a central heat source for calculation of spreading resistance from Ref. [16]

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Fig. 6

Thermal resistance network for internal cooling with a MHX

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Fig. 7

Predicted heat transfer into a cutting tool as a function of cutting speed for orthogonal turning of Ti–6Al–4V

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Fig. 8

Predicted tool-chip interface temperature as a function of cutting speed for orthogonal machining of Ti–6Al–4V for dry and various cooling strategies

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Fig. 9

Sensitivity of the tool-chip interface temperature calculation to friction coefficient, μ, and tool-chip contact length, a

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Fig. 10

Influence of 15% variation in the cutting speed, feed, and depth of cut on the tool-chip interface temperature

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Fig. 11

Effect of other variables on tool-chip interface temperature under internal cooling

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Fig. 12

Effect of other variables on tool-chip interface temperature under conventional cooling of water soluble metalworking fluid



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