A better understanding of cryogenic machining using CFD and FEM simulation

Abstract

Cryogenic machining has emerged as an environmental-friendly alternative to flood machining and minimum quantity lubrication. Cryogenic machining was also proven to improve tool life in some difficult-to-cut material such as Titanium alloys, where high temperature induced by machining leads to diffusion and adhesion wear and consequently limitations in tool life. This research aims to present a better understanding of the cryogenic effect on machining of Ti-6Al-4V using a combination of CFD simulations and FEM calculations. The research uses FEM calculations to obtain cutting temperatures and heat generation rates during the orthogonal cutting of Ti64, then uses these results as initial conditions in a CFD model to simulate the effect of a cryogenic jet of liquid carbon dioxide on the tool, chip and workpiece. The CFD model is used to analyze the effect of the temperature on the tool and chip to help understand the relation to tool wear. The research studies the interaction of the cryogenic CO2 during machining by varying position relative to tool-chip interface, and analyzes the effects of these variations on the resulting cutting temperatures.