Modeling for prediction of tool-chip interface temperature in internal cryogenic turning considering film boiling

Gan, Yongquan; Wang, Yongqing; Li, Kuo; Bo, Qile; Li, Haibo

doi:10.1016/j.ymssp.2022.109095

Cited by 4 publications

(1 citation statement)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…There are many advanced works concentrated on the modification and optimization of the cooling technology to reduce the cutting temperature and the influence of the Leidenfrost effect, such as low-temperature cooling, − high-pressure cooling, − minimum quantity lubrication technology, , and so on . For example, Sartori et al concluded that N 2 cooled at −100 °C has superior performance in terms of tool wear resistance and machined surface integrity.…”

Section: Introductionmentioning

confidence: 99%

Delayed Leidenfrost Effect of a Cutting Droplet on a Microgrooved Tool Surface

Guo

Liu

et al. 2023

Langmuir

View full text Add to dashboard Cite

Regulation over the generation of the Leidenfrost phenomenon in liquids is vitally important in a cutting fluid/tool system, with benefits ranging from optimizing the heat transfer efficiency to improving the machining performance. However, realizing the influence mechanism of liquid boiling at various temperatures still faces enormous challenges. Herein, we report a kind of microgrooved tool surface by laser ablation, which could obviously increase both the static and dynamic Leidenfrost point of cutting fluid by adjusting the surface roughness (Sa). The physical mechanism that delays the Leidenfrost effect is primarily due to the ability of the designed microgroove surface to store and release vapor during droplet boiling so that the heated surface requires higher temperatures to generate sufficient vapor to suspend the droplet. We also find six typical impact regimes of cutting fluid under various contact temperatures; it is worth noting that Sa has a great influence on the transform threshold among six impact regimes, and the likelihood that a droplet will enter the Leidenfrost regime decreases with increasing Sa. In addition, the synergistic effect of Sa and tool temperature on the droplet kinetics of cutting droplets is investigated, and the relationship between the maximum rebound height and the dynamic Leidenfrost point is correlated for the first time. Significantly, cooling experiments on the heated microgrooved surface are performed and demonstrate that it is effective to improve the heat dissipation ability of cutting fluid by delaying the Leidenfrost effect on the microgrooved heated surface.

show abstract

Section: Introductionmentioning

confidence: 99%

Delayed Leidenfrost Effect of a Cutting Droplet on a Microgrooved Tool Surface

Guo

Liu

et al. 2023

Langmuir

View full text Add to dashboard Cite

show abstract

Investigating the performance of the pressurized injection lubrication technique in the turning process

Elsadek

2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Efficient lubrication and cooling are crucial in machining operations to enhance tool life and workpiece quality. Sustainable methods like minimum quantity lubrication (MQL) and dry cutting often face limitations in cooling efficiency and chip evacuation, especially under high-speed conditions or when machining difficult-to-cut materials such as stainless steel. This study introduces the novel pressurized injection lubrication (PIL) technique designed to address these challenges by optimizing lubrication, cooling, and chip evacuation during the turning operations of stainless steel 304. Using flaxseed oil as the lubricant, the PIL system employs a 0.26 mm stream diameter at a pressure of 16 bar to provide the necessary cooling and lubrication to the cutting zone. Cutting temperature and surface roughness were selected as the primary responses. Experimental runs were designed using the Taguchi L9 method. Analysis of variance showed that the lubrication method significantly affected the cutting temperature, with a contribution percentage approaching 94%. The experimental results demonstrated that PIL reduced the cutting temperature by up to 55%, while MQL reduced it by about 48%, both compared to dry cutting at the highest utilized speed. The lubrication method was also found to be the most significant factor affecting surface roughness, with a contribution percentage of 72.8%. Experimentally, PIL improved surface roughness by a maximum of 16.2% compared to MQL. Additionally, PIL maintained low oil consumption (0.9 l/h) and energy usage (< 0.017 kWh). The cost-effective PIL setup, priced under 65 USD, underscores its potential as a sustainable and efficient alternative for machining processes. The system’s components are readily available, facilitating easy integration into existing metal-cutting machines. Finite element analysis (FEA) modeling was used to predict residual stresses under different lubrication methods. The FEA model indicated that PIL and MQL reduced residual stresses by about 81.2% and 76.6%, respectively, compared to dry cutting at a speed of 500 rpm. These findings suggest that PIL can significantly enhance machining performance and sustainability, offering a viable solution to modern manufacturing challenges.

show abstract

Tough-brittle transition mechanism and specific cutting energy analysis during cryogenic machining of Ti–6Al–4V alloy

Wang

et al. 2023

Journal of Cleaner Production

View full text Add to dashboard Cite

Modeling for prediction of tool-chip interface temperature in internal cryogenic turning considering film boiling

Cited by 4 publications

References 28 publications

Delayed Leidenfrost Effect of a Cutting Droplet on a Microgrooved Tool Surface

Delayed Leidenfrost Effect of a Cutting Droplet on a Microgrooved Tool Surface

Investigating the performance of the pressurized injection lubrication technique in the turning process

Tough-brittle transition mechanism and specific cutting energy analysis during cryogenic machining of Ti–6Al–4V alloy

Contact Info

Product

Resources

About