Development of pulse-assisted cryo-micro lubrication architecture for machining of Ti-based alloys: A frugal innovative attempt for a hybrid lubri-cooling technique

Abstract

In the present study, an Intermittent Spray Cooling (ISC) architecture has been developed for machining process applications for the first time. ISC is a newer cooling strategy through which cutting fluid is delivered into machining zone in a time-controlled pulsating mode. In order to enhance the machining performance for the least amount of coolant/lubricant consumption, the frugal design approach has been adopted including hybrid (liquid nitrogen (LN2) + minimum quantity lubrication (MQL)) cooling strategy and spray flow controller. Pulse assisted Cryo+MQL (PCMQL) integrated the application of a minimum quantity of mango seed oil (MSO) and liquid nitrogen (LN2) from two distinct nozzles in the machining zone. Therefore, to reveal the impact of PCMQL in turning of Ti-3Al-2.5 V, tool flank wear, cutting force, and surface roughness have been investigated. The obtained results have been compared with different environment conditions: dry cutting, MQL, pulse-MQL (PMQL) with 0.5 s pulse time, PMQL with 1 s, LN2, and hybrid Cryo+MQL. For comprehensive analysis, scanning electron microscopy (SEM), energy-dispersive spectrometer (EDS) has been used to analyze Ti-3Al-2.5 V chemical elemental deposition on flank face of the carbide cutting tool. The experimental results showed that PCMQL reduced the fluid consumption while attaining smooth surface finish, minimum flank wear and cutting force as compared to other environment conditions. The developed intermittent spray cooling system is an economical process and showed the positive impact on machining of titanium (Ti) alloys.