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

초록

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 degrees 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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