To eliminate health and environmental problems caused by using conventional cutting fluid in the machining industry, a new economical and practical approach to cryogenic machining technology was developed. Using micro nozzle jetting to the cutting point locally, this approach minimizes the amount of liquid consumption to levels at which nitrogen costs less than conventional cutting fluid. It reduces tool wear and lengthens tool life up to five times, thereby allowing for high-speed cutting, improving productivity and reducing overall production cost. In addition, this approach reduces the frictional force, improves chip breaking, eliminates build-up edge, and improves surface quality. This paper discloses the new cryogenic machining approach, and assesses the econom- ics of the process in comparison with state-of-the-art conventional emulsion cooling.

Issue Section:
Technical Papers
Keywords:
machining, cutting, cryogenics, cooling, machine tools, manufacturing processes, jets
Topics:
Cutting, Machining, Coolants, Cooling
1.
Bennett, E. O., 1992, “Dermatitis in the Metalworking Industry,” Special Publication SP-11, Society of Tribologists and Lubrication Engineers, Park Ridge, IL.
2.
Klocke
,
F.
, and
Eisenblatter
,
G.
,
1997
, “
Dry Cutting
”
Ann. CIRP Manuf. Technol.
,
46
, No.
2
, pp.
519
–
526
.
3.
Bartle
,
E. W.
,
1953
, “
Carbon Dioxide Permits Improved Machining Time
,”
Machinery (American)
,
59
, p.
157
157
.
4.
Delaney
,
R. J.
,
1957
, “
Sub-Zero Machining and Quenching
,”
Machinery (American)
,
63
, p.
148
148
.
5.
Hollins
,
W.
,
1961
, “
The Application and Effect of Controlled Atmosphere in the Machining of Metals
,”
Int. J. Mech. Tool Des. Res.
,
1
, p.
59
59
.
6.
Arundel
,
L.
,
1961
, “
Fast Cutting with Carbon Dioxide Coolant
,”
Prod. Eng. (N.Y.)
,
32
, pp.
266
–
267
.
7.
Reed
,
R.
,
1965
, “
Northrop Studies Production Techniques for Titanium
,”
Machinery (American)
,
71
, p.
79
79
.
8.
Filippi
,
A.
, and
Ippolito
,
R.
,
1971
, “
Face Milling at −180°C
,”
Ann. CIRP
,
19
, No.
2
, p.
399
399
.
9.
Uehara
,
K.
, and
Kumagai
,
S.
,
1970
, “
Characteristics of Tool Wear in Cryogenic Machining
,”
Ann. CIRP
,
19
, p.
273
273
.
10.
Evans
,
C.
,
1991
, “
Cryogenic Diamond Turning of Stainless Steel
,”
Ann. CIRP
,
40
, No.
1
, pp.
571
–
575
.
11.
Mitelea
,
I.
,
1990
, “
Austenitic Steels Cryogenic Cutting: A Method of Life Tools Improving
,”
Bull. Cerde ’Etud Metaux
,
15
, No.
20
, p.
20
20
.
12.
Wang
,
Z. Y.
,
Rajurkar
,
K. P.
, and
Fan
,
J.
,
1996
, “
Turning Ti-6A1-4V Alloy with Cryogenic Cooling
,”
Trans. NAMRC
, Vol. XXIV,
pp.
3
–
8
.
13.
Bhattacharayya, D., and Allen, M., 1991, “Cryogenic Machining of Kevlar Composites,” Processing and Manufacturing of Composite Materials, MD-Vol. 27, ASME, pp. 133–147.
14.
Chattopadhyay
,
A. B.
,
Bose
,
A.
, and
Chattopadhyay
,
A. K.
,
1985
, “
Improvements in Grinding Steels by Cryogenic Cooling
,”
Precis. Eng.
,
7
, p.
93
93
.
15.
Dillon
,
O. W.
,
Angelis
,
R. J. De
,
Lu
,
W. Y.
,
Gunasekera
,
J. S.
, and
Deno
,
J. A.
,
1990
, “
The Effects of Temperature on Machining of Metals
,”
J. Mater. Shap. Technol.
,
8
, p.
23
23
.
16.
Hong
,
S.
, and
Zhao
,
Z.
,
1992
, “
Cooling Strategies for Cryogenic Machining from Materials Viewpoint
,”
J. Mater. Eng. Perform.
,
1
, No.
5
, pp.
669
–
678
.
17.
Zhao
,
Z.
, and
Hong
,
S.
,
1992
, “
Cryogenic Properties of Some Cutting Tool Materials
,”
J. Mater. Eng. Perform.
,
1
, No.
5
, pp.
705
–
714
.
18.
Hong, S., Ding, Y., and Mathilakath, S., 1999, “Cryogenic Machining of Ti-6A1-4V, Part 2: Friction and Cutting Force,” submitted to Int. J. Mach. Tools Manuf.
19.
Hong, S., 1999, “Cryogenic Machining,” US Patent No. 5901623.
20.
Hong, S., Jeong, J., Chen, G., and Saksena, A., 1999, “Design of a Low Flowrate LN2 Delivery System for Economical Cryogenic Machining,” submitted to Int. J. Mach. Tools Manuf.
21.
ISO3685, 1993, “Tool Life Testing with Single-point Turning Tools.”
22.
Hong, S., and Ding, Y., 1999, “Cryogenic Machining of Ti-6A1-4V, Part 1: Cooling Approaches and Cutting Temperature,” submitted to Int. J. Mach. Tools Manuf.
23.
Hong
,
S.
,
1993
, “
Conclusion Report, Phase I, Economical Cryogenic Machining for High Speed Cutting of Difficult-to-machine Materials,” Technical Project Report to EMTEC.
24.
Machinability Data Center, 1980, “Machining Data Handbook,” 3rd Ed., Vol. 1, Metcut Associates, Cincinnati, Ohio, pp. 1–39.
25.
Hong, S., Marcus, I., and Ding, Y., 1999, “Cryogenic Machining of Ti-6A1-4V, Part 3: Cooling Approaches and Tool Lives,” submitted to Int. J. Mach. Tools Manuf.
26.
Hong
,
S.
,
Ding
,
Y.
, and
Ekkens
,
R. G.
,
1999
, “
Improving Low Carbon Steel Chip Breakability by Cryogenic Chip Cooling
,”
Int. J. Mach. Tools Manuf.
,
39
, No.
7
, pp.
1065
–
1085
.
Copyright © 2001
 by ASME
You do not currently have access to this content.