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A novel indirect cryogenic cooling system for improving surface finish and reducing cutting forces when turning ASTM F-1537 cobalt-chromium alloys

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Abstract

This paper presents a novel indirect cryogenic cooling system, employing liquid nitrogen (LN2) as a coolant for machining the difficult-to-cut ASTM F-1537 cobalt-chromium (CoCr) alloy. The prototype differs from the already existing indirect cooling systems by using a modified cutting insert that allows a larger volume of cryogenic fluid to flow under the cutting zone. For designing the prototype analytical and finite element, thermal calculations were performed; this enabled to optimize the heat evacuation of the tool from the rake face without altering the stress distribution on the insert when cutting material. Turning experiments on ASTM F-1537 CoCr alloys were performed under different cutting conditions and employing indirect cryogenic cooling and dry machining, to test the performance of the developed system. The results showed that the new system improved surface roughness by 12%, and cutting forces were also reduced by 12% when compared with the existing indirect cryogenic cooling technique.

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Abbreviations

Ø eff :

Effective diameter of the tool (m)

t :

Top wall thickness of the insert (m)

w :

Sidewall thickness of the insert (m)

L INS :

Side length of the cutting insert (m)

t insert :

Thickness of the cutting insert (m)

Ft :

Frictional force (N)

V s :

Sliding velocity (m/s)

V c :

Cutting speed (m/min)

f :

Feed (mm/rev)

a p :

Depth of cut (mm)

F c :

Cutting force (N)

F f :

Feed force (N)

F p :

Passive force (N)

\( \dot{Q\ } \) :

Heat transfer rate (W)

\( {\dot{q}}_t \) :

Heat transfer rate from chip to the tool (W)

ξ :

Fraction of the energy generated at the tool-chip interface that remains with the chip material

a :

Thermal diffusivity (m2/s)

c p :

Specific heat (J/kg K)

T CHIP :

Temperature of the chip (K)

T RAKE :

Temperature at the rake face of the tool (K)

T CRYO :

Temperature of the cryogenic media at the back of the tool (K)

R SPR :

Spreading thermal resistance on the rake face of the tool

R COND :

Conductive thermal resistance of the tool insert

R BOIL :

Convective thermal resistance of the nitrogen in the gas phase

R CONV :

Convective thermal resistance of the nitrogen in the liquid phase

k :

Thermal conductivity (W/(m K))

k t :

Thermal conductivity of the tool (W/(m K))

h :

Convective coefficient (W/(m2 K))

h N2 :

Convective coefficient of nitrogen in the gas phase (W/(m2 K))

h LN2 :

Convective coefficient of nitrogen in the liquid phase (W/(m2 K))

A cav :

Surface available for heat exchange in the cavity generated in the tool insert (m2)

L c :

Characteristic length of the of the body to which the heat is being transferred to

Nu :

Nusselt number

μ :

Friction coefficient

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Acknowledgements

The authors of this report would like to express their very great appreciation to Mr. Dylan Khor from Tungaloy Cutting Tool (Thailand) Co., Ltd. for providing all the cutting tools necessary for the project; to Haimer Asia Pacific Ltd. for providing the tool holder required to perform the modifications, and in like manner to Mr. Cha-Hliang Goonjam, Application Manager from Makino (Thailand) Co. Ltd. for carrying out the manufacturing operations in the cutting tools which were essential for this project. The authors would also like to thank the Basque Government for the support provided by the PROCODA project (Code KK-2019/00004).

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Authors and Affiliations

  1. Mondragon Unibertsitatea - Faculty of Engineering, Loramendi 4, 20500, Arrasate, Spain

    Iñigo Rodriguez Bogajo & Pedro José Arrazola

  2. Center of Excellence for Prosthetic and Orthopedic Implant, Department of Mechanical Engineering, Faculty of Engineering, Chulalongkorn University, Phayathai Road, Pathumwan, Bangkok, 10330, Thailand

    Pairat Tangpronprasert, Chanyapan Virulsri & Saran Keeratihattayakorn

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  1. Iñigo Rodriguez Bogajo
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  2. Pairat Tangpronprasert
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  3. Chanyapan Virulsri
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  5. Pedro José Arrazola
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Correspondence to Iñigo Rodriguez Bogajo.

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Bogajo, I.R., Tangpronprasert, P., Virulsri, C. et al. A novel indirect cryogenic cooling system for improving surface finish and reducing cutting forces when turning ASTM F-1537 cobalt-chromium alloys. Int J Adv Manuf Technol 111, 1971–1989 (2020). https://doi.org/10.1007/s00170-020-06193-x

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