Simulation of Cryo-cooling to Improve Super Alloys Cutting Tools

Abstract

Improve machining processes from an environmental point of view is a hot topic currently. In this line, cryogenics CO2 is presented as a solution to substitute conventional oil emulsions. However, to be applied industrially, it is needed to control CO2 flow rate with the aim of reducing CO2 consumption to reach what it is known as ECO2-performance (economy + ecology). Then, despite currently CO2 cooling technique is used as external coolant, it is needed to improve its use—especially in milling processes—for achieving this goal. In line with this, in this paper is presented the use of CO2 as tool internal coolant as a solution to optimize its use. For checking its suitability, a study based on computer fluid dynamics with a new cryogenic tool channels design and experimental tests were carried out for analyzing the differences between using CO2 as internal and external coolant with the aim of improving the use of cryogenic gases during Inconel 718 milling processes. The results show that the use of CO2 as internal coolant improves the current milling process not only from environmental point of view but also economic and technical, bringing CO2 cryogenic technology closer to industrial milling conditions.