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Economic evaluation and machining performance in Ti-6Al-4V titanium alloy milling by integrated CO2 & MQL injection system

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Abstract

In this study, a twin-fluid atomizing nozzle was fabricated to inject an integrated mixture of minimum quantity lubrication (MQL) mist and cryogenic gases, such as CO2 and LN2, to the machining area of the tool in the milling of (Ti-6Al-4V) titanium alloy. The machining performance of the nozzle was analyzed by evaluating the cutting temperature, cutting force, and tool wear. The integrated injection of CO2 and MQL mist was then compared with other cutting fluid application techniques, such as dry machining, cryogenic gas injection, and MQL mist for an economic evaluation. The experimental results revealed that this integrated injection reduced the cutting temperature by approximately 23 % (at 100 °C) for the same flow rate, while rarely occurred tool wear for the same cutting volume. Although it incurs an additional cost for the CO2 cryogenic gas and MQL mist, it effectively reduces the cutting tool wear as compared to other cutting fluids, under the same cutting conditions and flow rate. It also increases productivity and reduces cost by improving the machining performance.

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Authors and Affiliations

  1. R&D Center, HARANG AMI Inc., Incheon, Korea

    Seok-Jae Ha

  2. Department of Mechanical Engineering, Inha University, Incheon, Korea

    Dong-Wook Lim & Ji-Hun Kim

  3. Shape Manufacturing R&D Department, Research Institute of Advanced Manufacturing and Materials, Korea Institute of Industrial Technology, Incheon, Korea

    Jeong-Yeon Park

  4. Department of Design Die and Mold, Korea Polytechnics, Incheon, Korea

    Ki-Hyeok Song

Authors
  1. Seok-Jae Ha
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  2. Dong-Wook Lim
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  3. Ji-Hun Kim
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  4. Jeong-Yeon Park
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  5. Ki-Hyeok Song
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Corresponding author

Correspondence to Ki-Hyeok Song.

Additional information

Seok-Jae Ha received his M.S. and Ph.D. degrees in Mechanical Engineering from Inha University, Incheon, Korea, in 2010 and 2015. He is currently the Head of R&D Center at HARANG AMI Inc. His research interest includes cutting monitoring, MR fluid polishing, micro machining, and fabrication of device for biomedical applications.

Ki-Hyeok Song received his M.S. and Ph.D. degrees in Mechanical Engineering from Inha University, Incheon, Korea, in 2015 and 2020. He is currently a Professor at the Department of Mold Design at Korea Polytechnic. His research interest includes cutting monitoring, micro machining and ultrasonic machining.

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Ha, SJ., Lim, DW., Kim, JH. et al. Economic evaluation and machining performance in Ti-6Al-4V titanium alloy milling by integrated CO2 & MQL injection system. J Mech Sci Technol 35, 4135–4142 (2021). https://doi.org/10.1007/s12206-021-0825-4

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  • DOI: https://doi.org/10.1007/s12206-021-0825-4

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