Progressive Tool Wear in Cryogenic Machining: The Effect of Liquid Nitrogen and Carbon Dioxide

Abstract

This experimental study focuses on various cooling strategies and lubrication-assisted cooling strategies to improve machining performance in the turning process of AISI 4140 steel. Liquid nitrogen (LN2) and carbon dioxide (CO2) were used as cryogenic coolants, and their performances were compared with respect to progression of tool wear. Minimum quantity lubrication (MQL) was also used with carbon dioxide. Progression of wear, including flank and nose, are the main outputs examined during experimental study. This study illustrates that carbon dioxide-assisted cryogenic machining alone and with minimum quantity lubrication does not contribute to decreasing the progression of wear within selected cutting conditions. This study also showed that carbon dioxide-assisted cryogenic machining helps to increase chip breakability. Liquid nitrogen-assisted cryogenic machining results in a reduction of tool wear, including flank and nose wear, in the machining process of AISI 4140 steel material. It was also observed that in the machining process of this material at a cutting speed of 80 m/min, built-up edges occurred in both cryogenic cooling conditions. Additionally, chip flow damage occurs in particularly dry machining.