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* Email: dhanachezian@yahoo.co.in
Email: pradeep@annauniv.edu
2
Department of Production Technology, Anna University Chennai, India.
Email: rajadurai@annauniv.edu
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Abstract
Cutting temperature is the determining factor for other machinability indices of material. The conventional cutting fluids are
ineffective in controlling the cutting temperature in the cutting zone. Cryogenic cooling is environmental friendly new approach for
desirable control of cutting temperature. Current work involved the experimental study of the effect of cryogenic cooling on cutting
temperature, cutting force, chip thickness and shear angle in the orthogonal machining of AISI 1045 steel and Aluminium 6061-T6
alloy. It has been observed that in cryogenic cooling method, the temperature was reduced to 1928% and the cutting force was
increased to a maximum of 15% then dry machining of AISI 1045 steel. In machining of Aluminium 6061-T6 alloy, the temperature was
reduced to 2739% and the cutting force was increased to a maximum of 10%.
Keywords: Orthogonal machining, Cryogenic cooling, Cutting temperature, Cutting force.
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I. INTRODUCTION
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RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009
Aluminium 6061-T6 alloy. The effectiveness of cryogenic
cooling was compared with that of dry machining.
III. EXPERIMENTAL CONDITIONS AND PROCEDURE
Table 1.
Experimental conditions.
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Parameter
Group I
Group II
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Work material
Diameter (mm)
80
80
Length (mm)
250
250
Cutting tool
Un coated carbide
54 and 193
54 and 193
Environment
Compressor
Drier
Pressure
Regulator
Presure
relief valve
Insulated stainless
steel hose
Nozzle
Pneumatic
hose
Stainless
steel pipe
56
Stainless
steel cap
Stainless
steel pipe
RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009
The comparison of cutting force for AISI 1045
steel and Aluminium 6061-T6 alloy with feed rates for
different cutting velocities under dry and cryogenic
machining were shown in Figure 3 and 4 respectively. It
clearly appears that cutting force increases with the
increase in feed rate due to increase in chip load and also
cutting force decreases with the increase in cutting speed
due to decrease in shearing area. The result indicates that
increased cutting force in cryogenic machining over dry
machining in all cutting conditions. The purpose of using
liquid nitrogen as cooling medium is to lower the cutting
temperature in the cutting zone. The workpiece material
becomes harder and less sticky at lower temperature and
thus resulting in an increased cutting force and reduction
in adhesion between chip-tool interface. The influence of
cryogenic cooling increases the cutting force to a
maximum of 15% and 10% for the machining of AISI
1045 steel and Aluminium 6061-T6 alloy respectively.
1200
1000
800
600
400
200
0
0
0.05
0.1
0.15
0.2
350
300
Table 2.
Reduction in cutting temperature due to cryogenic machining.
250
200
150
Cutting velocity - 54m/min (Dry)
S.No
Cutting
Velocity
(m/min)
Feed rate
(mm/rev)
1
2
3
4
5
54
54
54
193
193
0.079
0.119
0.159
0.079
0.119
193
0.159
Reduction in cutting
temperature (%)
Aluminium
AISI 1045
6061-T6
steel
alloy
27.61
39.05
26.17
37.30
25.20
35.12
22.67
32.64
21.20
30.26
19.57
100
0
0
0.05
0.1
0.15
0.2
27.98
57
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RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009
feed rate and also the decrease in chip thickness with the
increase in cutting speed. The reduction in chip thickness
was observed to be maximum of 15% and 25% in
cryogenic machining of AISI 1045 steel and Aluminium
6060-T6 alloy respectively. This is because of better
lubrication effect produced by the liquid nitrogen at the
chip-tool interface due to the formation of fluid cushion.
Reduced the chip thickness in cryogenic machining
results from the lowered cutting temperature and reduced
adhesion between the tool and chip.
Dry cutting
Cryogenic cutting
25
20
15
10
0
0.079
0.119
(a)
0.5
Dry cutting
Cryogenic cutting
30
0.4
25
0.3
0.159
0.6
0.2
Cutting velocity - 54m/min (Dry)
Cutting velocity - 54m/min (Cryogenic)
0.1
20
15
10
5
0
0
0.05
0.1
0.15
0.2
0.079
0.119
0.159
Fig. 5. Variation in chip thickness with feed rates under dry and
cryogenic machining of AISI 1045 steel.
(b)
0.6
Fig. 7. Shear angle vs. feed rate at different cutting velocities for
AISI 1045 steel (a) 54 m/min (b) 193 m/min.
0.5
Dry cutting
Cryogenic cutting
25
0.3
20
0.2
Shear angle (degree)
0.4
0.1
15
10
0
0
0.05
0.1
0.15
0.2
Fig. 6. Variation in chip thickness with feed rates under dry and
cryogenic machining of Aluminium 6061 T6 alloy.
0.079
0.119
0.159
(a)
Dry cutting
Cryogenic cutting
25
20
15
10
0
0.079
0.119
0.159
(b)
Fig. 8. Shear angle vs. feed rate at different cutting velocities for
Aluminium 6061-T6 alloy (a) 54 m/min (b) 193 m/min.
V. CONCLUSION
Experiments on orthogonal cutting of AISI 1045
steel and Aluminium 6061-T6 alloy were carried out
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RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009
2.
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4.
REFERENCES
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