Simulation of the effects of cryogenic liquid nitrogen jets in Ti6Al4V milling

Albertelli, Paolo; Strano, Matteo; Monno, Michele

doi:10.1016/j.jmapro.2022.11.053

Cited by 12 publications

(4 citation statements)

References 77 publications

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“…As a result, the temperature of the workpiece and the milling force fluctuate widely. Thermal softening of the material occurs after 0.03 s, the milling force and milling temperature fluctuate up and down around a fixed value, and the cutting force distribution is consistent with that of Albertelli P [43]. To obtain a relatively more accurate three-way milling force and milling temperature, the maximum value is taken in the period of 0.05 s~0.1 s (as in Figure 7).…”

Section: Milling Force and Milling Temperature Data Processingmentioning

confidence: 86%

Aero-Engine Blade Cryogenic Cooling Milling Deformation Simulation and Process Parameter Optimization

Chen,

Xu,

Huang

et al. 2023

Materials

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For the machining of aero-engine blades, factors such as machining residual stress, milling force, and heat deformation can result in poor blade profile accuracy. To address this issue, simulations of blade milling were completed using DEFORM11.0 and ABAQUS2020 software to analyze blade deformation under heat-force fields. Process parameters such as spindle speed, feed per tooth, depth of cut, and jet temperature are used to design both a single-factor control and BBD test scheme to study the influence of jet temperature and multiple changes in process parameters on blade deformation. The multiple quadratic regression method was applied to establish a mathematical model correlating blade deformation with process parameters, and a preferred set of process parameters was obtained through the particle swarm algorithm. Results from the single-factor test indicated that blade deformation rates were reduced by more than 31.36% in low-temperature milling (−190 °C to −10 °C) compared with dry milling (10 °C to 20 °C). However, the margin of the blade profile exceeded the permissible range (±50 µm); therefore, the particle swarm optimization algorithm was used to optimize machining process parameters, resulting in a maximum deformation of 0.0396 mm when the blade temperature was −160 °C~−180 °C, meeting the allowable blade profile deformation error.

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Section: Milling Force and Milling Temperature Data Processingmentioning

confidence: 86%

Aero-Engine Blade Cryogenic Cooling Milling Deformation Simulation and Process Parameter Optimization

Chen,

Xu,

Huang

et al. 2023

Materials

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“…To address this issue, a nite element model is created using the ABAQUS nite element simulation software to simulate the dicing process. This work investigates the elastic deformation rules of soft elastic materials during dicing at varying temperatures [23], [24]. μm A number of nite element models for continuous dicing are established in this work to examine the relationship between the dicing forces F x , F y , and workpiece deformation during the dicing process, as shown in Fig.…”

Section: Finite Element Model Of Millingmentioning

confidence: 99%

Study on the Machining Accuracy of Soft Elastic Material Using Cryogenic Dicing

Yu,

He,

et al. 2024

Preprint

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Dicing is one of the common processing methods for soft elastic materials. However, as the processing dimensions continue to decrease, the machining accuracy of the workpiece becomes worse. In this work, a three-dimensional (3D) finite element model (FEM) of dicing processing is established by using finite element software ABAQUS and is compared with experimental results. Based on the established 3D dicing FEM, the influence of temperature, depth of cut, and spindle speed on the dicing process is studied. The results show that in the traditional soft elastic material dicing process, the increase in spindle speed and the decrease in processing dimensions led to the vibration of the tool, tilt and twist deformation of the workpiece, which become the main reasons for the poor machining accuracy. The application of cryogenic processing can effectively suppress the tilt and twist deformation of the workpiece. Under high spindle speed, cryogenic dicing can also somewhat mitigate the negative influence of tool vibration.

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“…In the literature, many researchers have studied the effect of cryogenic LN 2 on processing. Albertelli et al (2023) proposed a 3D finite element simulation model of Ti6Al4V milling with internal delivery of LN 2 . They found that the main cutting forces were reduced (on average by 22%) due to cryogenic cooling, which also produced more damaged and fragmented chips.…”

Section: Introductionmentioning

confidence: 99%

Research on liquid nitrogen cryogenic milling of 11Cr-3Co-3W martensitic heat-resistant steel

Lü

Deng

Tang

et al. 2023

ILT

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Purpose When processing 11Cr-3Co-3W martensitic heat-resistant steel, the traditional pouring cooling method often appears large cutting force, high cutting temperature, serious tool wear and poor surface quality. This paper aims to use new cooling methods for processing this problem. Design/methodology/approach Different performance indicators such as cutting force, tool wear and surface quality were measured and analysed under different continuous milling times. The relationship between liquid nitrogen flow and cutting force and surface roughness was analysed and measured. Findings The results show that with the increase of liquid nitrogen flow, the cutting force decreases, especially the Fx component, which decreases by 10%. When the liquid nitrogen flow reaches 8 L/min, the effect of increasing the liquid nitrogen flow on reducing the cutting force becomes smaller. The cutting force reduced by up to 15%, and the tool life increased up to 20% using liquid nitrogen cryogenic cooling than in cutting liquids cooling. When minimal quantities of lubricant (MQL) was added, the cutting force was reduced by 23%, and the tool life increased by 25%. When the cutting speed increases from 100 m/min to 250 m/min, the cutting force with cutting liquid cooling does not change significantly while the cutting force with liquid nitrogen cooling decreases with the cutting speed increasing. It shows that liquid nitrogen cooling is more suitable for high-speed machining. After the cutting length reaches 66 m, the surface roughness of the workpiece using liquid nitrogen cooling method larger than that of the cutting liquid cooling method. When MQL is added into liquid nitrogen, the lubrication performance is improved, and the surface roughness of the workpiece is reduced about 8%. Originality/value Many studies had focused on the improvement of tool life and surface quality by different cooling methods, or on the injection process and chip mechanism. However, there are few relevant studies on the variation of cooling and lubrication properties with the change of cutting length in liquid nitrogen cryogenic processing. In this research, different performance indicators such as cutting force, tool wear and surface quality were measured and analysed under different continuous milling times. The relationship between liquid nitrogen flow and cutting force and surface roughness was analysed and measured. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2023-0053/

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Simulation of the effects of cryogenic liquid nitrogen jets in Ti6Al4V milling

Cited by 12 publications

References 77 publications

Aero-Engine Blade Cryogenic Cooling Milling Deformation Simulation and Process Parameter Optimization

Aero-Engine Blade Cryogenic Cooling Milling Deformation Simulation and Process Parameter Optimization

Study on the Machining Accuracy of Soft Elastic Material Using Cryogenic Dicing

Research on liquid nitrogen cryogenic milling of 11Cr-3Co-3W martensitic heat-resistant steel

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