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Research Papers

A Hybrid Modeling Approach for Characterization and Simulation of Cryogenic Machining of Ti–6Al–4V Alloy

[+] Author and Article Information
Bin Shi

Aerospace Manufacturing
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Bin.Shi@cnrc-nrc.gc.ca

Ahmed Elsayed

Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mail: Ahmed.Korashy@mail.mcgill.ca

Ahmed Damir

Aerospace Manufacturing
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Ahmed.Damir@cnrc-nrc.gc.ca

Helmi Attia

Aerospace Manufacturing Technology Centre
(AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada;
Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mails: Helmi.Attia@ cnrc-nrc.gc.ca;
Helmi.Attia@mcgill.ca

Rachid M'Saoubi

Materials and Technology Development,
Seco Tools AB,
Springfield Business Park,
Alcester B49 6PU, Warwickshire, UK
e-mail: Rachid.Msaoubi@secotools.com

1Corresponding author.

Manuscript received April 30, 2018; final manuscript received December 14, 2018; published online January 4, 2019. Assoc. Editor: Karl R. Haapala.

J. Manuf. Sci. Eng 141(2), 021021 (Jan 04, 2019) (8 pages) Paper No: MANU-18-1286; doi: 10.1115/1.4042307 History: Received April 30, 2018; Revised December 14, 2018

A hybrid modeling approach based on computational fluid dynamics (CFD) and finite element method (FEM) is presented to simulate and study cryogenic machining (CM) of Ti–6Al–4V alloy. CFD analysis was carried out to study the characteristics of the fluid flow and heat transfer process of liquid nitrogen (LN2) jet used as a coolant in turning operation. The velocity, turbulence, gas volume fraction, and temperature of the impingement jet were investigated. Based on the analysis results, the coefficient of heat transfer (CHT) between the LN2 and cutting tool/insert was obtained and used in the FEM analysis to model the heat transfer process between the LN2 and the tool/chip/workpiece. A three-dimensional (3D) finite element (FE) model was developed to simulate a real CM operation. CM tests were carried out to validate the 3D FE model by comparing cutting forces and chip temperature. To evaluate LN2 cooling effect on tool temperature and tool wear, a two-dimensional (2D) FE model was developed for steady-state thermal analysis of cryogenic and dry machining. Based on the predicted temperatures, the tool wear was estimated, showing that LN2 cooling can significantly improve tool life.

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References

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Figures

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Fig. 1

Overview of (a) the turning operation model with external supply of LN2 and (b) the simplified 2D model of the LN2 jet and the hot target/tool

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Fig. 2

CFD simulation results for (a) velocity streamline, (b) TKE, and (c) pressure at the stagnation point

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Fig. 3

CFD simulation results for (a) temperature field, (b) liquid fraction, and (c) temperature distribution in the target

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Fig. 4

Description of 3D FE model for CM

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Fig. 5

(a) Turning setup and (b) IR temperature measurement

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Fig. 6

Predicted temperature fields on (a) insert and (b) workpiece/chip

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Fig. 7

Comparison of simulation and measured cutting forces

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Fig. 8

A 2D FE model of CM

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Fig. 9

Predicted steady-state temperature fields under dry and LN2 conditions

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Fig. 10

Temperature distributions along (a) rake face and (b) flank face

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Fig. 11

Predicted tool wear rate versus temperature for WC/Ti–6Al–4V tribosystem

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