Nozzle Configuration Research Articles

Experimental and numerical simulations to examine the mechanism of nozzle geometry affecting cavitation water jets

The geometry of the cavitation nozzle is the major determinant of the cavitation process and cleaning effect. To better service the cleaning industry, it is necessary to understand the process by which nozzle geometry impacts cavitation. This research uses experimental flow visualization and large eddy simulation (LES) to study the cavitation effects of three different nozzle configurations (Cylindrical, organ-pipe and converging–diverging nozzles). The shedding frequency of the cavitation cloud was determined through power spectrum analysis (PSD). The collapse range of the cavitation cloud produced was measured using the frame difference technique (FDM). A cleaning experiment was carried out to remove the tube scale with the aim of assessing the performance of the nozzle. The findings indicate that under the impact of the re-entrant jet, the cavitation cloud was distorted and fractured, and large shear stresses were produced at the fracture sites. The cylindrical nozzle creates a flow field with more vapour, velocity, and Reynolds stress than the other two nozzles. The findings from the cleaning experiments indicate that the utilization of appropriate nozzle geometry and an optimal standoff distance can significantly enhance the efficiency of tube descaling. This paper can help choose the right nozzle geometry and standoff distance for the cavitation water jet cleaning process, offer crucial technical support for the efficient cleaning within tubes.

The Effect of Water Jet Overlaps in a Descaler on the Quality of Surface of the Hot Rolled Steel

Hot rolling is a highly efficient steel processing method involving the heating and subsequent rolling of semi-finished cast products within mills; however, heating results in the formation of an undesirable, inhomogeneous oxide layer on the surface. Removal of this layer, known as scales, prior to rolling is essential to prevent scales from being rolled into the surface. The scales are removed in the descaler. Most descalers use multiple high-pressure hydraulic descaling nozzles with overlapping sprays. This setting can cause excessive cooling in the overlap area, uneven descaling of the surface, and the presence of residual scales. It can also result in uneven cooling at the finishing line. This study illustrates a typical nozzle configuration commonly used in industrial plants in the hydraulic descaling process and compares its results with a new configuration. The research focuses on examining the overlap area and the washout area of the sprays. The goal is to address the inhomogeneous descaling problem and propose procedures to prevent residual scales. It was shown that one of the problematic areas is the washout area, where the average thickness of the remaining scales was more than four times higher than other descaling areas. Reducing the offset angle has proven to be a good way to eliminate the washout area and achieve a homogeneous descaling process.

Numerical investigation on atomization characteristics of sustainable aviation biofuel

It is critical to investigate the atomization features of sustainable aviation biofuel (SAF) to reduce carbon emissions. Fluent software was used to quantitatively simulate the atomization of the fuel. The control variable method was utilized to compare SAF to Chinese aviation fuel RP-3. The volume of fluid model (VOF) and the discrete phase model (DPM) were used to explore the variation law of SAF atomization characteristics in a two-way centrifugal nozzle with a pressure drop of 2–8 MPa and various nozzle configurations. The experimental results suggest that the model is effective. The results demonstrate that when pressure increases, the average diameter of SAF’s Sauter mean diameter reduces from 80 to 23 µm and the spray penetration distance increases from 0.32 to 0.6 m, allowing for more stable fuel combustion. Meanwhile, as the nozzle outlet aspect ratio increases, such as increasing the nozzle diameter from 2.0 to 2.6 mm, the atomization cone angle varies from 60° to 110° and gradually declines, although the average diameter of Sauter only varies minimally within a limited range of 30–40 µm. All of these findings indicate that SAF has good atomization properties and the potential to be used as an aviation fuel.

Closing the Loop: Toward Sustainable 3D Print Recycling in the Clinic

THREE-DIMENSIONAL (: 3D) printing is becoming ubiquitous in Radiation Therapy resulting in large amounts of plastic waste generated. We report on the feasibility, workflows, material properties and cost effectiveness of 3D print recycling to increase sustainability of 3D printing in clinics. Polylactic acid (PLA) prints were recycled using a consumer-grade recycling system consisting of i) plastic shredder to granulate used prints ii) heated extruder to melt material into filament iii) fan-cooled path for rapid cooling iv) spooling rig and v) pelletizer to cut filament into more regularized pellets as input material for step ii). The recovery percentage of material was characterized after each step by weighing inputs/outputs; timing and workloads were also recorded. Resulting recycled filaments were characterized in diameter and tensile strength and were compared between two different extruder nozzle configurations and with vs without pelletization to find an optimal recycling process. Recycled filament was finally used to create clinical items and evaluated. Lastly, a cost analysis over the past 1 year of recycling use was performed to determine the cost effectiveness of the recycling system. PLA prints were recycled with an overall efficiency of 79.3 ± 12.2% (standard deviation) between color batch runs. The best recycled filament quality was produced using the pelletization process and wider 3.25mm extruder nozzle. Relative to new filament, tensile strength testing showed recycled filament strength was 79% vs 70% (pelletized vs unpelletized) and 86% vs 60% (3.25mm vs 2.85mm nozzle). Extrusion and spooling procedures proved difficult to optimize, requiring lots of operator supervision (∼45 minutes per spool, mean 475g) and achieved a best filament diameter of 2.85 ± 0.09mm. A cost analysis shows that without accounting for operator time, it would require over 25 years to recoup the cost of the recycling system. Over the past 1-year, clinical 3D printing at our site consisted of 40 patient boluses and 25 electron cutouts, consuming about 6.5kg of PLA. Due to infection control concerns only 35% of this material was eligible for recycling, however 3.5 times that amount was collected from other printing activities. Recycling reduced new filament use by 56% ($470). Recycling workflows proved difficult to streamline and resulted in filament diameter that was marginally outside common industry standards and about 20% less strong but deemed adequate for clinical printing. Although the cost savings analysis indicates a poor return on investment, increasing the scale of the operation would be beneficial. To achieve this, we plan to recycle PLA boluses after disinfection and solicit other clinics in our hospital network and local 3D printing hobbyist community to recycle their prints.

Base Flow and Drag Characteristics of a Supersonic Vehicle with Cold and Hot Jet Flows of Nozzles

Base drag has a significant effect on the overall drag of a projectile in a supersonic flow. Herein, the base drag and flow characteristics of cold and hot gas flow in a supersonic flow are analyzed via numerical simulations. The hot gas flow is simulated using a chemical equilibrium application code based on hydrogen combustion. Two types of nozzle configurations, namely conical and contoured, are chosen for the simulation. The simulation results reveal that the change in base drag is 5–85% according to the injection gases. In the over-expanded and slightly under-expanded conditions, the base drag decreases in the hot gas flow, owing to the weak expansion fan caused by the high-temperature nozzle flow expansion, whereas in the highly under-expanded condition, the base drag decreases, owing to the strong shock wave near the base caused by the deflection of the recirculation region toward the body wall. In addition, the variations in base flow structures are observed differently compared with the cold flow; for example, a weak oblique shock wave at the nozzle exit, an increase in the distance between the shock wave and base, and deflection of the recirculation region based on the body wall are observed.

Reynolds-Number Effects on the Acoustic Disturbance Environment in a Mach 6 Nozzle

To understand the impact of the Reynolds number on the disturbance field inside a high-speed wind tunnel, we use direct numerical simulations to model turbulent boundary layers along the walls of a quasi-two-dimensional nozzle configuration. These simulations are performed at four different unit Reynolds numbers, ranging from to . The predominantly hydrodynamic fluctuations inside the boundary layer are nearly unaffected by the freestream forcing of the impinging acoustic radiation from the opposite wall. Within the nozzle-core region, the disturbance environment is found to be spatially uniform and solely acoustic in character. Comparisons with tunnel noise measurements are made using the numerical data. For the first time, comparisons of fluctuations in the same physical quantity (the streamwise mass flux) have been published, as opposed to earlier comparisons involving static-pressure fluctuations based on the simulations and pitot-pressure fluctuations recorded in the wind tunnel. The NASA 20 in. Mach 6 wind tunnel observations corroborate the predicted trend of decreased root-mean-square variations in pressure and mass flux as the Reynolds number rises. Additional details of the acoustic radiation field are quantified and should be useful toward a digital synthesis of the tunnel disturbance environment that would enable realistic simulations of the natural transition process.

Parameter study for oil spray cooling on endwindings of electric machines via Eulerian–Lagrangian simulation

The demand for larger power density and torque for the power traction motors used in electrified transportation puts forward a requirement for better thermal management methods. Spray cooling is a promising direct liquid cooling technique that has been proved to possess high heat removal capability in previous research. This paper investigates the heat transfer characteristics of spray cooling on endwindings of electric machines via numerical simulation through an Eulerian–Lagrangian approach. The utilized numerical models and calculated results are validated with experimentally measured data. The influence of different parameters and options involved in the simulation settings on the final results, like the stream numbers for the spray injector, the constant heat flux versus constant temperature thermal boundary condition, the influence of splashing, the effect of heat conduction in the endwindings and the Saffman lift force, only solving the energy equation for the air after its flow field reaches a steady-state, are evaluated. Parameter analyses are also conducted for operation conditions, configuration of the spray nozzles, and material properties of the coolant liquid. It is found that larger flow rate, smaller droplet size, lower spray height, more nozzle numbers, larger thermal conductivity and smaller viscosity of the coolant liquid tend to increase the overall heat transfer performance.

Improvement of Fingering-Induced Pattern Collapse by Adjusting Chemical Mixing Procedure

Pattern collapse, also as known as leaning, has become one of the most common and challengeable defects in semiconductor manufacturing process due to device shrinkage. In single wafer wet cleaning, Isopropyl Alcohol (IPA) rinse is widely used after Deionized Water (DIW) rinse. Fingering instabilities are observed at the mixing boundary of IPA and DIW, where dry spots are formed due to unbalanced capillary force amid patterns. Unlike previous DRAM devices, we have found that recent 1x-nm DRAM devices have become more vulnerable to pattern collapse induced by dry spots related to fingering instability. In this paper, we examine factors and phenomenon related to fingering-induced leaning through both experiments and simulation analysis. In addition, we also propose improved rinsing methods which could prevent fingering and related pattern collapse by adjusting nozzle configurations (i.e. speed, flow rate and etc.).

Influence of nozzle geometry on screech instability closure

The effect of nozzle exit geometry on the triadic interactions between convective Kelvin–Helmholtz instabilities and the quasi-steady shock structure of supersonic jets is discussed in this study. A circular and rectangular nozzle with an aspect ratio (AR) of 2 were evaluated using results from near field acoustics and high-speed Schlieren images. The study investigated different types of screech instabilities in both nozzle configurations, including the multimode instability in rectangular jets. The near field acoustic measurements showed comparable trends in screech staging in both nozzle configurations. The Schlieren results revealed that the standing waves in the jet near field were influenced by the oscillation mode of the jets. The study also explored a new technique of noise visualization from Schlieren images based on near field acoustics and temporal Fourier decomposition. Spatial Fourier decomposition demonstrated that the resonance closure mechanism across both nozzle configurations was dependent on the relative influence of the first two shock cells. Comparisons between the AR 2 and AR 9 jet showed that jet aspect ratio can significantly affect the energy distribution from the triadic interactions.

Survey of Semi-Empirical Jet Noise Models for Preliminary Aircraft Engine Design

Scientific research studies on jet noise generation have been ongoing since the early 1950s, when turbojets were first used in commercial aircraft. Several numerical methods have been developed with the aim of reducing the environmental issues related to the impact of jet noise on community annoyance. Among them, the development of fast and comprehensive tools for jet noise prediction captured the attention of researchers and engineers, being very useful in the preliminary design phase of aircraft engines. This work deals with an extensive survey of James R. Stone’s models, initially formulated for the National Aeronautics and Space Administration (NASA) by Modern Technologies Corporation (MTC), and their implementation in a contemporary numerical framework. The models and their implementation are validated by simulating different engine settings and nozzle configurations taken from the literature with the main scope of highlighting the strengths and weaknesses of the different semi-empirical formulations and setting guidelines for their effective use during the design phases of the next generation of supersonic aircraft.

Assessment of the depressurization and mixing effects of two spray systems in the PANDA facility, part I – Experimental results

The spray safety system is one of the most effective solutions to limit the pressure and temperature rise in the containment of a nuclear power plant during a design basis accident. However, its actuation under severe accident conditions may have either a positive effect on the hydrogen risk by mixing the containment atmosphere and avoiding high H2 local concentrations or a negative impact by condensing the steam and de-inerting the atmosphere. The experiments performed during the OECD/NEA HYMERES-2 Project aimed to extend the experimental database dedicated to assessing the capabilities of the codes used to optimise the operation of the safety systems. Specifically, the H2P5 series consisted of two experiments that compared the activation of a central full cone spraying nozzle (H2P5_2) with nine smaller spraying nozzles, eight equally distributed at 0.5 m from the metallic walls of PANDA (H2P5_1). The ninth nozzle was positioned in the vessel vertical axis for the latter configuration. H2P5_1 was the first experiment ever using a multiple nozzle configuration in PANDA, which was aimed to address the conditions expected in a plant containment with droplets interacting with the vessel walls as well as with each other.The measurements indicated a considerable difference between the two configurations regarding the pressure and temperature decay, which signified the presence of non-adiabatic effects. The stronger cooling of the walls measured during H2P5_1 resulted in a slower depressurisation for most of the test duration. This can be explained by an intensified interaction of the injected droplets (by direct droplet-wall interactions or by potential formations of liquid films) and the vessel walls, which was coherent with the use of the spray ring in H2P5_1. It was also shown that the different spray configurations (type of nozzles and nozzles distribution) had a significant impact on the gas mixing. The measurements of the mass spectrometer available during the tests revealed a non-obvious initial faster mixing for the single nozzle experiment, which is approximately five times faster compared with the nozzle array.

Effects of magnetic nozzle strength and orientation on radio-frequency plasma expansion

To improve the efficiency of radio-frequency magnetic nozzle plasma thrusters, it is important to better understand the coupling between plasma expansion and a convergent–divergent magnetic field. This study explores the effects of magnetic field strength and orientation on plasma expansion in a magnetic nozzle. Two-dimensional measurements of the plasma characteristics obtained both in the source and in the expansion region are presented to investigate the influence of magnetic field strength on the formation of high-density conics in a symmetric magnetic nozzle. The measurements are repeated in a deflected magnetic nozzle using a novel magnetic steering system. Measurements of the ion saturation current and floating potential profiles are used respectively to qualitatively assess the plasma density distribution and the presence of high-energy electrons for the magnetic field configurations analysed. In the symmetric magnetic nozzle configuration, it is observed that the ion saturation current peaks on axis in the plasma source, but downstream of the nozzle throat, a double-peaked hollow profile is observed for all cases studied. The location of the high-density conics structure matches the most radial field lines that intersect the antenna and can freely expand downstream outside the source. Negative values of the floating potential are measured in the same peripheral regions, which could be a sign of the presence of high-energy electrons. When the magnetic field is deflected, the ion saturation current profile shows only a single peak centred around the bent field line that reconnects to the antenna. Again, a region of negative floating potential is measured at the location of the maximum ion current. Thus, it is shown how, independent of magnetic field strength and orientation, the magnetic field lines interacting with the antenna dictate the local plasma profiles downstream from the magnetic nozzle.

Improving the performance of indirect evaporative cooler for energy recovery from the perspective of nozzle configuration: A CFD model analysis

As a sustainable cooling technology, indirect evaporative cooling (IEC) has been widely recognized as an effective means of achieving carbon neutrality based on its low energy consumption and high efficiency in central air conditioning (AC) systems of buildings. In contrast to the conventional arrangement, IECs as heat recovery units are often arranged in a diamond shape inside the air handling units (AHUs) of data centers (DCs), an approach that facilitates the flexible use of space and integration within the units in a more compact form. The use of CFD simulations allows an integrated analysis of the coupling of hydrodynamic, thermal and mass properties helps to improve the evaporation performance of IECs. In this study, a 3D simulation model of a diamond-shaped IEC containing the water spray system was developed to compare and analyze the air-water arrangement options in IEC systems currently used in DCs, and the corresponding characteristics are explored from the perspective of CFD techniques to determine the effect of nozzle configurations on the formation and evaporation of water film within the wet channels. Then, parametric analysis of nozzle setup schemes based on performance metrics showed that the nozzle arranged in top-side configuration and paired with the air-water counterflow form had the best performance, with 59.2% and 27.4% improvement in water film coverage area and temperature drop, respectively, over the worst scheme (bottom configuration) at a water supply flow rate of 65 L/s. Finally, the effectiveness of the enhanced approach was simulated and analyzed for hydrophilic and fiber coatings, and it was found that the water film coverage increased by 14.5% and 31.6%, respectively, while the coefficient of performance (COP) increased by 7.4% and 16.1%.

High-performance thermal management system for high-power LEDs based on double-nozzle spray cooling

Thermal management is one of the main challenges for high-power LEDs. As one of the state-of-the-art thermal management approaches, spray cooling can meet the requirements of fast cooling speed, large heat transfer coefficient, and less energy consumption when it provides thermal management for electronics with high heat flux. In this study, a high-performance spray cooling system for high-power LEDs is designed and established. The influence of nozzle configuration, flow rate, and nozzle-to-surface distance on the heat transfer characteristics are experimentally and numerically investigated. The system shows excellent heat dissipation capacity. Two different nozzle configurations are compared and the results show that the double-nozzle configuration possesses the highest single-phase heat transfer coefficient, reaching up to 20.7 kW/m2·K with the flow rate of 150 mL/min. Interestingly, double-nozzle, which owns better heat transfer performance compared to single-nozzle, shows worse temperature uniformity inside the testing module. Simultaneously, the junction temperature of double-nozzle at the center chip can also be controlled to 85 °C corresponding to a 10% reduction for single-nozzle. The proposed cooling system may enable the further application of spray cooling in electronics like high-power LEDs, potentially reducing the energy consumption in cooling electronics and promoting the utilization of low-grade thermal energy.

Droplet spatial distribution of oil-based emulsion spray

Introduction Oil-based emulsion solution is a common pesticide formulation in agricultural spraying, and its spray characteristics are different from that of water spraying. The well understanding of its spray characteristics is the theoretical basis to improve the pesticide spraying technology. The objective of the present study is to deepen the understanding of the spray characteristics of oil-based emulsion. Method In this paper, the spatial distribution characteristics of spray droplets of oil-based emulsion were captured visually using the high-speed photomicrography. On the basis of image processing method, the droplet size and distribution density of spray droplets at different spatial locations were analyzed quantitatively. The effects of nozzle configuration and emulsion concentration on spray structures and droplet spatial distribution were discussed. Results Oil-based emulsion produced a special perforation atomization mechanism compared with water spray, which led to the increase of spray droplet size and distribution density. Nozzle configuration had a significant effect on oil-based emulsion spray, with the nozzle changed from ST110-01 to ST110-03 and ST110-05; the sheet lengths increased to 18 and 28 mm, respectively, whereas the volumetric median diameters increased to 51.19% and 76.00%, respectively. With emulsion concentration increased from 0.02% to 0.1% and 0.5%, the volumetric median diameters increased to 5.17% and 14.56%, respectively. Discussion The spray droplet size of oil-based emulsion spray can be scaled by the equivalent diameter of discharge orifice of nozzles. The products of volumetric median diameters and corresponding surface tensions were nearly constant for the oil-based emulsion spray of different emulsion concentrations. It is expected that this research could provide theoretical support for improving the spraying technology of oil-based emulsion and increasing the utilization of pesticide.

Modeling and comparison of the powder flow dynamics for tilted annular and discrete-outlet nozzles in laser directed energy deposition

The Laser Directed Energy Deposition (L-DED) process is gradually maturing as an Additive Manufacturing (AM) technique. It provides substantial advantages for the refurbishment, redesign or coating of high-value components, which in general, are also large in volume and mass. For such components, it becomes necessary the use of a positioner which keeps the nozzle in a normal orientation as it is displaced over the different components’ surfaces. There is little understanding on the implications of tilting the nozzle on the process efficiency, as well as on the impact of using different nozzle configurations. This work presents a detailed Computational Fluid Dynamics (CFD) analysis of the powder stream generated by two widely used types of powder-fed coaxial nozzles: annular and discrete three-outlet nozzle. For different cases of nozzle orientation, the effect of mass flow and volumetric gas flow on particle velocity and powder convergence, are analyzed. This is crucially contrasted when the two nozzle types are taken into account. Further to analyzing stream behavior, this work also presents process maps for predicting powder usage rates. It was found that the powder usage is significantly affected by the nozzle type, mass and gas setting. For instance, for the case of a narrow 1.0 mm–wide melt pool in a 90°tilt, the annular nozzle is able to achieve up to 75.0% of powder capture efficiency, whereas for the three-outlet nozzle, this usage drops to 36.0%.

Flow dynamics and noise generation mechanisms in supersonic underexpanded rectangular and planar jets

In this study, large eddy simulations of two rectangular jets with different aspect ratios and one planar jet with spanwise periodic boundaries are carried out in an attempt to investigate and clarify some key issues regarding the flow dynamics and noise generation mechanisms for the screech tone. The substantial effects of the nozzle configuration on shock structures and noise are first revealed in detail. It is found that when the lateral confinement is weakened, the spacing of the shock cells increases and the jet oscillates more intensively in the minor-axis plane, increasing the noise level and altering the screeching frequency. By analyzing the pressure fluctuations of the shear layer in the wavenumber-frequency space, different kinds of waves in these supersonic jets are examined. Importantly, it is revealed that the guided jet wave should play a dominant role in closing the resonance loops rather than the acoustic wave. Moreover, the energy-containing structures with pertinent frequencies are extracted by employing the reduced-order variational mode decomposition, and some underlying flow dynamics are presented. Especially, a novel mechanism has been identified: the low-frequency stretching motions of shock cells have a significant modulation effect on the screeching amplitude in the planar jet. Furthermore, with the aid of the multi-process acoustic theory, the characteristics of physical noise sources are diagnosed, particularly the source mechanisms related to the screech tone. The general structures and distribution of the kinematic noise source Sβ and entropy noise source Se are presented. Sβ mainly exhibits a vortex-like structure near the nozzle, while Se exhibits a lamellar bilayer structure. The spatiotemporal correlations between the physical sources and far-field noise show that the dominant mechanisms for the screech tone rely on the nozzle configuration and the screech tone tends to be produced by multiple sources in all cases.

The circulation growth of non-impulsive starting jet

An analytical model that can be used to predict the circulation growth process for non-impulsive starting jets has been developed by extending the over-pressure correction model for impulsive starting jets. Only the jet velocity function U0(t) is needed to obtain the circulation growth process of non-impulsive starting jet. The non-impulsive starting jets generated by nozzle and orifice configurations are performed numerically with two acceleration schemes (represented by two kinds of velocity functions) and different acceleration stage stroke ratios LaD (modifying the acceleration time ta in each velocity function to obtain LaD=0.05:0.2:1.25) to verify the accuracy of the proposed analytical model. The influence of radial velocity distribution in the jet inflow boundary is ignored in the process of constructing this model, but this has been proven to be reasonable. The time-averaged relative error with the growth process of the total circulation predicted by this model is about 11% to 26%, which is smaller than the 44% to 88% obtained by the classical slug model. For the range of LaD from 0.05 to 1.25, the relative error with the prediction of the total circulation at the end of the acceleration stage is from 4% to 28%, as compared to the 39% to 96% for the slug model.

Investigation of gas purging configuration in an industrial ladle by computational fluid dynamics

A three-dimensional model was developed to investigate the effects of gas nozzle configuration in an industrial gas-stirred ladle on flow pattern, mixing time, heat transfer, inclusion removal, and shear stress on the wall. Population balance model coupled with computational fluid dynamics was chosen to evaluate the inclusion removal. The properties of phases and the size distribution of inclusion were in agreement with literature data. Gas nozzle locations were investigated in terms of radius and angle. It was found that an increase in angle and decrease in radius of gas nozzle location decreased shear stress on the wall. Also, as gas nozzle locations got closer to each other, bubble plumes overlapped, and turbulent kinetics was affected. This in turn affected temperature, mixing time, and inclusion removal. Therefore, by changing angle and radius, these parameters did not have similar trends. From the performed investigations, it was found that the best gas injection location was angle of 140° and radius of 0.65R. Shear stress, mixing time and inclusion removal at ladle with the plug radius of 0.65R were improved by 38.7%, 1.3%, and 0.87%, respectively. In addition, at ladle with the plug angle of 140°, shear stress, mixing time, and inclusion removal were increased by 6%, −6.57%, and 8%, respectively. By choosing this gas injection location, ladle performance was optimum in all parameters.

A numerical investigation on coolant flow and heat transfer characteristics of cutting tool in spot cooled vibration assisted turning of Ti6Al4V alloy

The present work is aimed to investigate the coolant flow and heat transfer of an uncoated carbide cutting tool in Spot Cooled Vibration Assisted Turning (SCVAT) of Ti6Al4V alloy. Initially, Ti6Al4V alloy was machined with SCVAT and the cutting temperature was determined using embedded thermocouple technique with a calibrated K-type thermocouple. This experimental data was utilized to validate the CFD model developed and the error in prediction is found to be within the satisfactory limits. A detailed CFD analysis is performed on dual nozzle impingement cooling system with CO2 as coolant. Then the effect of various nozzle variables viz. nozzle inclination (α), nozzle tool distance (β) and nozzle diameter (D) and coolant flow variables viz. coolant pressure (CP) and cold fraction (CF) on coolant flow pattern, temperature distribution, heat transfer coefficient and turbulence kinetic energy are investigated using the validated CFD model. Flow visualization revealed the formation of a recirculation zone in the vicinity of the cutting tool which may be attributed to the jet-to-jet spacing resulting from nozzle configuration. The maximum temperature at the tool work interface, temperature distribution along the flank and rake faces, heat transfer coefficient and Turbulence Kinetic energy are significantly affected by coolant pressure and cold fraction whereas the contribution of nozzle variables is comparatively less. This may be due to the significant influence of coolant pressure and cold fraction on coolant velocity and mass flow rate that result in efficient heat transfer from the cutting tool. Among the nozzle variables, nozzle diameter and nozzle tool distance are found to be significant whereas nozzle inclination is not significant. Furthermore, the effective nozzle configuration (α = 30⁰; β = 25 mm; D = 5 mm) and flow parameters (CP = 9 bar and CF = 30%) were determined for maximizing the heat transfer from the cutting tool.