Abstract
Manufacturing craves for more sustainable solutions for machining heat-resistant alloys. In this paper, an assessment of different cooling lubrication approaches for Ti6Al4V milling was carried out. Cryogenic cutting (liquid nitrogen) and conventional cooling (oil-based fluid) were assessed with respect to dry cutting. To study the effects of the main relevant process parameters, proper energy models were developed, validated and then used for comparing the analysed cooling lubrication strategies. The model parameters were identified exploiting data from specifically conceived experiments. The power assessment was carried out considering different perspectives, with a bottom-up approach. Indeed, it was found that cryogenic cooling, thanks to a better tribological behaviour, is less energy demanding (at least 25%) than dry and conventional cutting. If the spindle power is considered, lower saving percentages can be expected. Cryogenic cooling showed its best energy performance (from 3 to 11 times) with respect to conventional cutting if the machine tool perspective is analysed. Considering even the primary energy required for producing the cutting fluids, the assessment showed that cryogenic cooling requires up to 19 times the energy required for conventional cutting.
Highlights
Titanium components are widely adopted in many high-performance applications, ranging from biomechanical to aerospace, its machinability is still a stimulating challenge both for manufacturing industries and for the research community [1]
Since for the adopted cutting condition at maximum one tooth is engaged in the piece, the following expressions can be used for computing the average cutting power:
The power involved in machining, the power absorbed by spindle, the power linked to the machine tool system and the primary power were considered
Summary
Titanium components are widely adopted in many high-performance applications, ranging from biomechanical to aerospace, its machinability is still a stimulating challenge both for manufacturing industries and for the research community [1]. Due to high chemical reactivity, low thermal conductivity and high material strength that is preserved at high temperatures, titanium and other heat-resistant alloys HRA are considered hard-to-cut materials. Water miscible and oil-based cutting fluids (namely, conventional cooling) are the most widely diffused solutions for processing HRA in shop-floors. It was productivity and machining costs are still the main drivers in machining technology development, in recent years, environmental sustainability [5] and health issues [6, 7] have been gaining an increasing attention. Adler et al [8] analysed the main limitations of the existing cooling lubricating CL methodologies
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