Abstract
The application of conventional cooling lubricants for the tribological conditioning of machining processes involves high additional costs and health risks. The application of a cryogenic carbon dioxide (CO2) snow cooling strategy is an economical and environmentally sound alternative for oily cooling emulsions since it has a high cooling effect as well as a residue-free sublimation. This article introduces a laser additive manufactured tool holder with an integrated dual nozzle which enables CO2-snow jet application. Initially this work focuses on the characterization and the selection of a suitable nozzle geometry. The modular tool body features an adapted channel structure for process-reliable and targeted CO2-snow cooling for turning processes. This enables the simultaneous cooling of the rake and flank face with CO2-snow, as well as the application of cryogenic multi-component cooling of the rake face. In the context of this study, the focus lies on the technological evaluation of three different supply strategies during the continuous turning of compacted graphite iron CGI-450 at increased cutting speed. It was established that an efficient rake face cooling is indispensable to achieve a low thermal tool load, and thus lower crater wear behavior. Therefore, this study contributes to an improvement in cryogenic machining processes regarding the design of additively manufactured tool bodies for process-reliable CO2-snow cooling, as well as for the selection of supply strategies to minimize the thermomechanical tool load.
Highlights
Carbon dioxide (CO2), in the form of CO2-snow, and liquid nitrogen (LN2) are preferably used for the cryogenic cooling of machining applications [1]
Abele and Schramm [8] examined the performance of poly-crystalline diamond (PCD) and carbide cutting tools during the turning of vermicular cast iron while CO2-snow jets were applied to the rake face side
An additively manufactured turning tool holder with increased functionality and modular design is presented in this work, which, in addition to the simultaneous process cooling with CO2-snow on the rake face as well as on the flank face, enables the application of cryogenic multi-component cooling on the rake face
Summary
Carbon dioxide (CO2), in the form of CO2-snow, and liquid nitrogen (LN2) are preferably used for the cryogenic cooling of machining applications [1]. Current studies in the area of machining of difficult-to-cut alloys, focus on the design of externally applied nozzle concepts for the supply of CO2 in combination with MQL For this purpose, Pereira et al [15] carried out CFD simulations to examine the open jet behavior of CO2 single component nozzles depending on the nozzle geometry. This work presents new design possibilities using a selective laser melting process to integrate a dual nozzle geometry into a modular tool holder to exploit the potential of cryogenic cooling and to apply it in a targeted and process-reliable way. An additively manufactured turning tool holder with increased functionality and modular design is presented in this work, which, in addition to the simultaneous process cooling with CO2-snow on the rake face as well as on the flank face, enables the application of cryogenic multi-component cooling on the rake face.
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