Cryogenic Machining of Titanium Ti-5553 Alloy PDF

Journal of Manufacturing Science and Engineering.
Received June 26, 2018;

Accepted manuscript posted January 01, 2019. doi:10.1115/1.4042605
Copyright © 2019 by ASME
Insert ASME Journal Title in the Header Here
Cryogenic Machining of Titanium Ti-5553

Alloy
Yusuf Kaynak1
Department of Mechanical Engineering, Technology Faculty, Marmara University,
Goztepe Campus, Kadikoy,34722, Istanbul-TURKEY
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yusuf.kaynak@marmara.edu.tr, yusuf_kaynak@yahoo.com
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ASME Membership Number: 000100060982
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Armin Gharibi
Department of Mechanical Engineering, Institute of Pure and Applied Sciences,
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Marmara University, Goztepe Campus, Kadikoy,34722, Istanbul-TURKEY
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armin.gharibi@gmail.com
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ABSTRACT
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Titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) is a new generation of near-beta titanium alloy that is
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commonly used in the aerospace industry. Machining is one of the manufacturing methods to produce
parts that are made of this near-beta alloy. This study presents the machining performance of a new
generation near-beta alloys, namely Ti-5553, by focusing on a high-speed cutting process under cryogenic
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cooling conditions and dry machining. The machining experiments were conducted under a wide range of
cutting speeds, including high speeds that used liquid nitrogen (LN2) and carbon dioxide (CO2) as cryogenic
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coolants. The experimental data on the cutting temperature, tool wear, force components, chip
breakability, dimensional accuracy and surface integrity characteristics are presented and was analysed to
evaluate the machining process of this alloy and resulting surface characteristics. This study shows that
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cryogenic machining improved the machining performance of the Ti-5553 alloy by substantially reducing
the tool wear, cutting temperature and dimensional deviation of the machined parts. The cryogenic
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machining also produced shorter chips as compared to dry machining.

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Keywords
Titanium Ti-5553 alloy, Cryogenic machining, Machining performance, Surface integrity
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1
Corresponding author information can be added as a footnote.
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Journal of Manufacturing Science and Engineering. Received June 26, 2018;
INTRODUCTION
In recent years, titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) has attracted the
attention of the aviation industry [1]. It has been used since 2005 to fabricate the large
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structural components in the landing gear for 787 airframes because it has a high yield
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strength, excellent fatigue crack growth resistance, good hardenability and corrosion
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resistance [1-3]. The mechanical properties of Ti-5553, such as its enhanced strength
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(approximately 1250 MPa at room temperature for certain types of microstructures)
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and high cycle fatigue compared to Ti-6Al-4V, make it an ideal candidate for a number of
applications [4]. This alloy is especially applicable for thick section aerospace
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components due to its deep-hardenability that is caused by its slower precipitation
kinetics [4]. Although this new generation titanium alloy has certain advantages in terms
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of mechanical and physical properties, there are issues with its forming processes,
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including machining and cutting. The other properties of Ti-5553, such as a low thermal
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conductivity, chemical reactivity, high strength at elevated temperatures and low

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modulus of elasticity [5] make it difficult to machine [6].

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The challenges in machining Ti-6Al-4V alloys include the tendency to weld to the
cutting tool during machining as a result of a chemical reaction, an increased cutting

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temperature due to the low thermal conductivity and reduced tool life [6]. The Ti-5553
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alloy that has a much higher strength, and can potentially cause additional problems
during the cutting process. However, chip formation processes that include turning,
milling and drilling during fabrication of products made from this alloy are essential.
Thus, problems in cutting process need to be resolved. Consequently, an investigation of

the chip formation process in the Ti-5553 alloy is required to determine the challenges
and develop appropriate approaches to optimize the machining process.
The main issue is that Ti-5553 is a relatively new alloy for industrial applications
and research about its machining performance is very limited. To the best knowledge of
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the authors, there is very little work that has focused on machining processes and the
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machining-induced surface integrity of this alloy [7-13]. Also, to the best knowledge of
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the authors, there has been no systematic and extensive study to understand the role of
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cryogenic coolant on chip formation that particularly focuses on the turning operation
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of this alloy. It is well known that during the machining of such aerospace alloys, the
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cooling method might play a critical role in improving the machining performance and
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controlling the surface characteristic [14]. Cryogenic cooling can decrease the
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temperature during the cutting process and increase tool life [15, 16]. In the literature,
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both liquid nitrogen and carbon dioxide were considered as cryogenic coolants to be
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utilized in metal cutting processes [16, 17]. The use of liquid nitrogen and carbon
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dioxide in machining processes for different materials was presented in various studies
[17, 18]. Based on the literature, cryogenic cooling seems to be a promising approach
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for fabricating difficult-to-machine materials, including Ti-based and Ni-based alloys [19-
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21].
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A few researchers studied the cutting process for Ti-5553 by utilizing liquid
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nitrogen [10]. However, the missing critical point in these studies is the contribution of
the cooling method (liquid nitrogen and carbon dioxide) at a wide range of cutting
speeds. Indeed, at a reasonable temperature, a conventional coolant might still be used.

However, better cooling is required for high cutting speeds, where the cutting
temperature can reach high values and cause issues with the chip formation process. A
high temperature also affects the microstructural characteristics and phase state of the
alloy. This might lead to additional complex processes during the plastic deformation of
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this alloy because it has an 850 ºC beta transus temperature [4].
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The challenges with high temperatures during the machining of the Ti-5553 alloy
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are caused by the high cutting speeds and its low thermal conductivity (8.6 W/m °C) [8].
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The delivery of liquid nitrogen or carbon dioxide into the hot deformation zone might
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decrease the temperature significantly. This change would be expected to cause
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alteration of the surface and subsurface characteristics of the machined parts. Thus,
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investigating only the machining performance under cryogenic cooling conditions might
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not be helpful to evaluate the product quality. Additional analysis and examination of
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the surface and subsurface of machined Ti-5553 alloys might be very useful for
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researcher purposes and industrial applications.

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In this study, extreme and applicable machining conditions were selected to be
able to provide useful data to both academia and industry. The maximum temperature
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is expected to be recorded during the dry cutting of engineering materials and the
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minimum temperature is expected to occur during cryogenic cooling conditions. Thus,

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this study has the potential to provide results for both the machining performance and
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surface integrity at both extreme conditions.
This study aimed to determine the chip formation process for the new beta
titanium alloy, Ti-5553, under a wide range of cutting speeds, including high speeds

under cryogenic cooling and dry conditions. The measured outputs for the machining
performance included wear rate, temperature, forces, chip breaking and surface
integrity characteristics, such as microhardness and phase transformation.
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EXPERIMENTAL PROCEDURES
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The workpiece used in this study was a round bar of a near β titanium alloy,
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namely Ti-5Al-5V-5Mo-3Cr-0.5Fe (Ti-5553), with a diameter of 20 mm and in the hot
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rolled condition. Elongation of the work material was 10% and the average hardness
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was measured to be 317 ± 5 HV. The thermal conductivity of this alloy was 8.6 W/m °C
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[8]. The microstructure of the Ti-5553 alloy is presented elsewhere [11]. It has a bimodal
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microstructure (BM) [22] that contains both the hcp α phase and bcc β phase [11].
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Because it has a bimodal microstructure, it contains a certain amount of globular α_p
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(primary α phase) particles [22]. Differential thermal analysis (DTA) and microstructure
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characterization of this material revealed the beta transus to be at around 845 °C - 850
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°C, according to various references [23, 24].

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Uncoated 883 grade carbide inserts, which are convenient for the machining of
superalloys with the ISO designation CNMG120408-M1, were used in this study. Its nose
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radius was 0.8 mm. The tool holder was PTJNL2525M16JET with a 95° approach angle,
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−6° normal rake angle and −6° end cutting edge angle. The machining experiments were
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conducted on a DOOSAN CNC turning centre with 18 KW power and maximum spindle
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speed of 4500 rpm. During the machining experiments, a constant feed rate, f, of 0.15
mm/rev, constant depth of cut, ap, of 1.2 mm, and five different cutting speeds, namely
30, 90, 120, 150 and 210 m/min, were utilized.

The machining experiments were conducted under dry machining conditions
without any coolant or lubricant. The cryogenic machining was done by delivering liquid
nitrogen and carbon dioxide through the tool holder. The liquid nitrogen was applied
under 1.5 MPa pressure and approximately 10 g/s mass flow rate. The pressure of the
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carbon dioxide was 5.4 MPa. The implementation of the liquid nitrogen and carbon
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dioxide during the machining process is shown in Figure 1. As shown in Figure 1, the
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liquid nitrogen and carbon dioxide were delivered through the rake face and flank face
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of the cutting tool.
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The cutting force components and tool wear were measured using a three-
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component piezoelectric KISTLER 2129AA dynamometer and Keyence digital optical
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microscope, respectively. The dimensional accuracy of each of the machined samples
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was measured using a Liberty LH 87 coordinate measurement machine. The

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measurements were repeated to minimize any error made by the user. The
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temperature around the cutting zone was monitored using an Optris PI 400 infrared
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camera and the emissivity of the work material was determined to be 0.63 [10]. To
validate that this emissivity value was applicable for this work material sample, the
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calibration was repeated. The work material sample was cooled and heated to a
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temperature range of − 50 to 600 °C by using the carbon dioxide coolant and Instron
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furnace, respectively [11]. At seven target temperatures within this temperature range,
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the work material’s temperature was measured with type K thermocouple that was
placed on it. It was simultaneously monitored with the infrared camera to validate the
calibration [11]. An example of the measured temperature profile is shown in Figure 2.

A Future-Tech FM-310e microhardness tester was used to measure the
microhardness of the machined surface and subsurface for the components with 25 gf
load. X-ray diffraction (XRD) analysis was conducted with a Bruker AXS D2 Phaser with
a CuKα1 wavelength, λ, of 1.54060 A ̇. The scanning 2θ angle was between 34° to 42°
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based on Bragg’s law.
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RESULTS AND DISCUSSION
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Machining temperature
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Heat is generated during machining by the work done in the plastic zone [25].
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Chips are formed and by friction at the tool-chip interface [25]. Thus, during the cutting
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process, high temperatures are generated in the region of the tool cutting edge, and
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these temperatures have a controlling influence on the rate of wear of the cutting tool
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and on the friction between the chip and tool [26]. Consequently, the tool life and
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cutting force components are affected by the generated temperature. In addition, the
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machined surface and subsurface are potentially influenced by the generated
temperature because it may alter the microstructure of the material. In contrast to

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many engineering materials, the high temperature is a concern for titanium alloys
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because of their low thermal conductivity, which is about 1/6 of steel’s thermal
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conductivity [27]. The heat builds up at the tool-chip interface and substantially affects
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machining process [27]. Cryogenic cooling seems to be one of the most promising
approaches to eliminate the detrimental effects of high temperature because it has a
temperature around -196 ºC [18, 28].

The temperature recorded during the cutting process under cryogenic cooling
conditions and dry machining is presented in Figure 3. The argument presented above is
supported by the obtained results. The recorded temperature difference in between the
dry and cryogenic cooling conditions is large. The dry machining almost doubled the
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cutting temperature compared to the cryogenic cooling. For instance, while the dry
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machining generated a temperature of 516 ºC temperature, machining with liquid
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nitrogen generated a 264 ºC temperature at the lowest cutting speed. This indicates that
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liquid nitrogen caused temperature reduction. This statement is true for the majority of
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the cutting speeds presented in here. The liquid nitrogen seems to be a much more
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effective cooling approach than the carbon dioxide based on the measured temperature
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values presented in this figure. The liquid nitrogen generated a much lower temperature
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at the higher cutting speeds, namely 150 and 210 m/min. Machining with liquid nitrogen
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generated 340 ºC at 210 m/min, whereas the maximum recorded temperature was 395
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ºC when machining with the carbon dioxide coolant.

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It should be noted that this temperature was the maximum recorded
temperature in the cutting zone but not at the tool-to-chip interface. Considering this
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point, it is possible to say that the real temperature at the tool-to-chip interface was
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expected to become much higher, but the difference between the cooled and dry
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machining was not expected to show a large difference. Overall, the cryogenic cooling
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utilizing both liquid nitrogen and carbon dioxide substantially reduced the temperature
compared to dry machining of the titanium Ti-5553 alloy.

Tool wear
The tool life or tool wear during the machining process of difficult-to-machine
materials are important parameters to evaluate to determine the machining
performance. This factor is important for manufacturing cost, the dimensional accuracy
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of the machined parts and surface quality [29]. However, it should be also noted that
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during the machining process of functional components, particularly components that
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are used in aerospace industry, the tool’s effect on the dimensional accuracy and
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surface characteristics of the components are a more significant concern than the cost
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of the cutting tool [30]. That is why, it is important to understand the progression of
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wear and associated wear mechanisms that take place during machining of such an
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alloy.
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The experimentally measured flank wear as a function of the cutting speed in dry
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and cryogenic cooling conditions is presented in Figure 4. No considerable difference in

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terms of flank wear was observed at a lower cutting speed for the three different
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conditions. The effect of cooling on a reduction of the tool wear is much more apparent
at higher cutting speeds, particularly 150 and 210 m/min. For instance, the carbon
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dioxide resulted in a 22% reduction, whereas the liquid nitrogen led to an approximately
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59% reduction in the maximum flank wear when the dry machining condition was taken
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as the reference. The difference in between liquid nitrogen and liquid carbon dioxide is
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mainly because of the temperature difference in these two cooling conditions. While
the temperature of liquid carbon dioxide is approximately -79 ºC, liquid nitrogen
temperature is much lower (its boiling point is approximately -196 ºC) [18, 20]. Thus, as

the cutting speed increased, the effectiveness of the liquid nitrogen became visible
when machining the Ti-5553 alloy. These results confirmed that at higher cutting
speeds, the cryogenic coolants were much effective at suppressing wear as compared to
the lower cutting speed.
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The tool-to-chip contact areas for the cutting tools used in the experimental
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study were also measured, and the obtained data is presented in Figure 5. The contact
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area as a function of cutting speed shows good agreement with the measured maximum
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flank wear when the cutting speed was 150 and 210 m/min. At the lower cutting speeds,
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the difference was negligible. At higher cutting speeds, the cooling conditions helped to
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reduce this area as compared to the dry machining process. At high cutting speeds, the
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measured tool-to-chip contact area needs to be considered as crater wear. As shown in
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the following images, the tool wear was obvious at higher cutting speeds on the rake
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face of the cutting tool. Again, liquid nitrogen made a substantial difference as
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compared to dry machining and reduced both the tool chip contact length and crater
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wear by approximately 45%. The carbon dioxide also reduced the wear and tool-to-chip
contact length as compared to dry machining, but it was not as effective as the liquid
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nitrogen.
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The two-dimensional profiles of the rake and flank faces for the cutting tools are
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presented in Figure 6. The geometry of the cutting tools used in the dry and carbon
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dioxide-assisted machining changed dramatically when considering the flank and rake
face as compared to a new and fresh tool.
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In addition, a large built-up-edge was observed during the dry machining. The
cutting tool used in liquid nitrogen-assisted machining did not seem to be worn out
throughout the tool-to-chip contact length. On the rake face of the cutting tool, local
plastic deformation was observed, as shown in Figure 7(c). This wear mechanism was
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also observed in the high-speed machining of a Ti-6Al4V alloy [6]. But the interesting
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finding is that while plastic deformation was observed in the liquid nitrogen-assisted
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machining, the diffusion and adhesion wear mechanisms dominated during the carbon
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dioxide-assisted machining of the Ti-5553 alloy. Adhesion also played a main role in the
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dry machining, as clearly shown in Figure 7.
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This part of the study demonstrated that after a certain cutting speed (150
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m/min and beyond), the tool wear was extremely severe and rapidly increased. The
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coolant was used to help reduce tool wear at even higher cutting speeds. Compared to
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carbon dioxide, it is apparent that liquid nitrogen was much efficient in reducing the tool
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wear. However, based on the observed tool wear results, 150 m/min cutting speed and
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beyond did not seem to be applicable in machining of this alloy.
This finding was related to the elevated temperature in the cutting zone that the
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cutting tool was subjected to. It is well known fact that carbide cutting tools lose their
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resistance and hardness at a certain temperature. According to the literature, the

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softening point for a carbide tool is approximately 1,100 °C [14]. It should be also noted
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that the hardness of a carbide cutting tool decreases more than 50% at around 800 °C
when compared to the hardness of carbide tool at the room temperature [14]. It is clear
that at the 150 m/min cutting speed, the recorded was is above 500 °C and it should be
11

noted that this temperature was not measured at the tool-to-chip interface where the
maximum temperature occurs. The increased temperature directly affects the wear
resistance of any material, as shown in the wear model below [31]:
𝐾 𝐹𝐿
𝑊= (1)
d
3 𝐻
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where W is the volumetric wear of the material, K is the Archard wear coefficient, F is
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the contact force, L is the cutting length and H is the hardness of the softest material
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[31], which in this case was the cutting tool. The only variables applicable to this work
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are the contact force and hardness of the cutting tool. Figure 8 shows the cutting tool’s
hardness as a function of the temperature changes. This temperature is the maximum
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that was measured in the cutting region but not at the tool-to-chip interface, where
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temperature should be much higher than the presented values. Nonetheless, these
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recorded temperatures can be still useful to show the difference. Considering the
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measured temperature during the dry cutting from 150 to 210 m/min, the hardness of
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the tool reduced approximately 16.5%, whereas during the cryogenic machining, the
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hardness reduced by approximately 3.5%. This large difference resulted in the large
difference in the tool wear that occurred during machining.

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This evidence supports the difference between the dry and cryogenic cooling
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conditions. Although the measured temperature variation for the carbon dioxide was
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close to the liquid nitrogen, the carbon dioxide did not provide an improvement in the
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wear resistance as the liquid nitrogen did. Figure 7 shows a CO2 cutting, in which there is
a large crater wear on the rake face of tool. This indicates that the temperature in
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between the tool’s rake face and chip was much higher than the temperature during the
liquid nitrogen-assisted cutting.
Force components
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Force components are the fundamental and significant indicators of the power
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requirements and energy consumption during machining processes. Force components
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are influenced by many parameters, such as tool–to-chip friction; properties of the
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work, tool and coating materials; the geometry of the cutting tool and cutting
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conditions, to name a few [32]. The obtained results from this study support the
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argument given in the previous sentence that the trend for the forces varies with both
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the cutting speeds and cutting conditions, as illustrated in Figure 9. While the main
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cutting forces were reasonably high at the lower cutting speeds, in all three conditions,
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it reduced as cutting speed increased. This change was attributed to the thermal effect,
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in which the increased cutting speed led to an increased temperature that helped to
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reduce the energy requirement to plastically deform the workpiece.
After a certain cutting speed, the trend completely changed and the force
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components increased as the cutting speed is increased. At the highest cutting speed,
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the maximum forces associated with the largest error bars were recorded. As shown in a
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previous section of this study, the tool wear rapidly increased as the cutting speeds (150
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m/min and beyond) led to increasing the force components as well. The effects of the
various cooling conditions and cutting speeds on the feed force and radial forces are
presented in Figures 10 and 11, respectively.
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At lower cutting speeds, the force variation in different conditions was not
notable, although the carbon dioxide generated slightly lower forces. However, a clear
difference was observed at higher cutting speeds in both the feed force and radial force
figures. The forces increased substantially in all three conditions. The liquid nitrogen had
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slightly higher feed forces at the lowest cutting speed and noticeably higher forces at
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the highest cutting speeds compared to the dry machining. However, carbon dioxide
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almost always lowered the feed and radial forces as compared to dry machining, as
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shown in Figures 10 and 11.
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The effects of the strain rate and temperature on the deformation response of
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the Ti-5553 alloy are presented in Figure 12. As shown in Figure 12(a), after a certain
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strain rate, the increased strain rate caused the forces to increase. Indeed, during
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machining, the strain rate is expected to be much higher than 1000 mm/s, so increased
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cutting forces with an increased strain rate are expected to be associated with an
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increased cutting speed. However, the temperature dominated the force required to
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plastically deform the work material, and consequently the forces reduced with an
increased cutting speed. This argument can be supported by the evidence provided in
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Figure 12(b), where increasing the temperature from room temperature to 600 ºC
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caused the force requirement for permanent deformation to reduce approximately

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50%; however, the increasing strain rate from 100 to 1000 caused an approximately
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10% increase in the force requirement.
The specific cutting force, (Ks), was calculated from the following equation [33]:
𝐹
𝐾𝑠 = 𝑎 𝑐.𝑓 (2)
𝑝
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where Fc is the main cutting force, ap is the depth of cut and f is the feed rate. The
material removal rate for each experiment was calculated using the following equation
[33]:
1000
𝑀𝑅𝑅 = 𝑎𝑝 . 𝑓. 𝑣𝑐 . (3)
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The calculated specific cutting forces and material removal rates are presented in Figure
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13. As shown in the figure, the minimum specific cutting forces were obtained with a
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120 m/min cutting speed, where the material removal rate was much higher than at the
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lower cutting speeds. At this cutting speed, tool wear was also close to the measured
minimum values. Thus, in terms of tool wear, energy requirement and material removal
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rate, this cutting speed provided the best performance among all selected cutting
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speeds.
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Chip breaking and thickness

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Chip control is an important issue in many machining operations, particularly in

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machining of ductile [33] or strain hardened work materials. Breaking chips into small
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and manageable sizes and shapes is a basic requirement for automated machining and
for disposing of chips for recycling and/or reuse [34]. Long and snarled chips with a large
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size are not desirable for the surface quality of the machined products and also for the
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prevention of tangling of the cutting tool [35]. For these reasons, smaller chips are
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desirable in the machining process. The chips resulting from various machining
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conditions and cutting speeds are illustrated in Figure 14. A large difference in the chip
breakability for the cooled and dry conditions is clearly seen in Figure 14. While dry
machining produces continuous, long and snarled chips at almost all cutting speeds, the
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liquid nitrogen and carbon dioxide help to produce shorter chips. These cooling
conditions also generated helical chips that were attributed to cooling effect.
The thickness of the collected chips was also measured, as presented in Figure
15. At a low cutting speed, the chips were much thicker than those produced at the high
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cutting speed for all three conditions. The increased cutting speed affected the shear
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angle in the deformation zone and changed the chip thickness. Among all three
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conditions, thinner chips were produced during dry machining while thicker chips were
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produced during the carbon dioxide-assisted machining process.
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Dimensional accuracy of machined parts
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The dimensional accuracy of machined aerospace alloys is one of the common
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quality concerns that needs to be strictly satisfied. The dimensional deviation that
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occurred after various machining conditions under two different cutting speeds is
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presented in Figure 16. It is an apparent that the dimensional accuracy of the machined
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parts was affected by the different conditions. While the maximum deviation from the
nominal diameter was measured on the parts machined in the dry cutting condition, the
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minimum deviation was obtained from the liquid nitrogen-assisted machining

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conditions. The cutting speed was also an effective way to obtain precious parts, as
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shown in Figure 16. Higher cutting speeds seemed to increase the dimensional deviation
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that was attributed to rapid tool wear at the nose region of the cutting tool. The
reduced tool wear with liquid nitrogen also helped to obtain machined parts with a
much higher dimensional accuracy.
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Surface integrity characteristics
In machining of Ti-5553, the surface integrity characteristics induced from chip
formation have not been comprehensively studied yet, but it is also beyond the scope of
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this study. However, in this study, two important characteristics of machining-induced
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surface integrity are discussed, namely the microhardness and XRD results. These two
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are expected to provide information about how the mechanical properties and phase
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state of the surface and subsurface are affected by the chip formation process under
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given conditions. Figure 17 shows the variation in the microhardness of components
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machined under dry and cryogenic cooling (liquid nitrogen and carbon dioxide)
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conditions at a cutting speed of 120 m/min. The results are consistent and indicate that
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the microhardness is not substantially affected by the cutting conditions. In all

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conditions, the microhardness of the parts decreased as compared to the hardness of

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the as-received work material. The softening was approximately 10% and in the closest
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layer to the surface. The depth of softened layer from the surface was approximately 80
µm. The role of various machining conditions on the softening response was not clearly
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discernible because all three were close to each other. However, this result showed that
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softening took place on the surface and subsurface of the machined Ti-5553 alloy.
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Figure 18 shows the XRD analysis of parts machined under dry and cryogenic
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cooling conditions (liquid nitrogen and carbon dioxide). Among all peaks in the XRD
pattern of the Ti-5553 alloy, the (100)α , (002)α , (101)α and (110)β are the dominant
reflection peaks, and the intensity of the other diffraction peaks was extremely low [22,
17

36]. For this reason, the area of interest was between 34o to 42 o 2θ because it includes
those mentioned peaks. The first observation from these results was that after
machining, the diffraction peak intensities decreased remarkably in all conditions.
Besides, the peaks from the machined parts broadened substantially as
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compared to peaks of the as-received material. The peak broadening was attributed to
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residual stress and/or grain refinement [36, 37] induced by the machining process.
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Among all three conditions, the (110)β peak was the broadest after liquid nitrogen-
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assisted machining . The (100)α diffraction peak disappeared for parts machined under
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all three conditions. This indicated that severe plastic deformation from the machining
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process led to the phase transformation from the alpha to the beta phase. However, it
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should be noted that the machining process itself mainly altered the XRD pattern of this
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alloy rather than the cooling conditions. It should be also noted that lubrication did not
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remarkably influence the surface integrity characteristics of the Ti-5553 alloy [40].
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Conclusions
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This study presented a comprehensive and systematic investigation of the
performance of the Ti-5553 alloy during a high-speed machining process under

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cryogenic cooling conditions and compared the results with dry machining. The
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following conclusions can be drawn from this study:

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- Cryogenic coolants substantially reduced the cutting temperature during the

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turning operation of this alloy.
- Up to the 120 m/min cutting speed, the tool wear was close for all three
conditions. The cryogenic coolants did not make a considerable difference.
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Above the 120 m/min cutting speed, an effective coolant was needed to
suppress the increasing tool wear. The experimental data provided evidence that
utilizing a cryogenic coolant, particularly liquid nitrogen, enabled the
implementation of high-speed machining of this material when considering tool
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wear.
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- Plastic deformation on the rake face dominated the tool wear mechanism during
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liquid nitrogen-assisted cryogenic cooling. On the other hand, the adhesion and
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diffusion were dominant during the carbon dioxide and dry machining processes.
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- In terms of material removal rate and specific cutting force, 120 m/min was the
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most preferable cutting speed among all selected cutting speeds in machining
tN
this alloy. Above the 120 m/min cutting speed, the force components suddenly
rip
increased due to extreme tool wear.

sc
- Compared to dry machining, the cryogenic cooling helped to shorten the chip
nu
lengths and improve the chip breakability for this Ti-5553 alloy.
Ma
- The reduced tool wear by the cryogenic coolants helped to reduce dimensional
deviation of the machined parts and improve the quality of the parts.
ed
- Regardless of cutting conditions, the machining process decreased the surface

pt
and subsurface hardness of the machined Ti-5553 alloy. The maximum reduction
ce
in the area closest to the surface was approximately 10%.

Ac
- The XRD analysis showed that the crystal structure and phases on the surface of
the machined material were affected from the machining process.
19

ACKNOWLEDGMENT
We would like to acknowledge TUBITAK (The Scientific and Technological Research
Council of Turkey) for its support to this work under project number 214M068. We also
thank to Mr. Emre Taşcıoğlu for helping us to plot the figures.
d
te
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22

Figure Captions List
Fig. 1. Experimental setup for cryogenic machining application

Fig. 2. Example of measured temperature profile
d
Fig. 3. Measured maximum temperature during machining under Dry, LN2 and CO2
te
conditions
Fig. 4. Measured maximum flank wear under Dry, LN2 and CO2 conditions
di
Fig. 5. Tool-chip contact area resulting from Dry, LN2 and CO2 machining conditions
Fig. 6. Cross section of cutting tools used under Dry, LN2 and CO2 conditions at 210
e
m/min and comparison with fresh tool
py
Fig. 7. 3-D images of cutting tools used in various conditions at 210 m/min cutting speed
Fig. 8. Temperature vs hardness relationship for tungsten carbide cutting tool, adapted
Co
from Groover [38]
Fig. 9. The main cutting force under Dry, LN2 and CO2 machining conditions at varying
cutting speeds
ot
Fig. 10. The feed force under Dry, LN2 and CO2 machining conditions at varying cutting
tN
speeds
Fig. 11. The radial force under Dry, LN2 and CO2 machining conditions at varying cutting
speeds
rip
Fig. 12. The effects of strain rate and temperature on deformation response of Ti-5553
alloy adapted from Germain et al [39]
sc
Fig. 13. Specific cutting forces and material removal rate under Dry, LN 2 and CO2
machining conditions at varying cutting speeds
nu
Fig. 14. Generated chips under Dry, LN2 and CO2 machining conditions at varying cutting
speeds
Ma
Fig. 15. Average chip thickness as a function of cutting speed for Dry, LN 2 and CO2
machining conditions
Fig. 16. Dimensional deviation of workpiece produced resulting from Dry, LN2 and CO2
ed
machining conditions
Fig. 17. The effects of various machining conditions on surface and subsurface
microhardness of machined parts at 120 m/min
pt
Fig. 18. XRD analysis of parts machined under dry, LN2, and CO2 conditions at 120 m/min
ce
cutting speed
Ac
23

FIGURES
d
Thermal camera
CO2
te
di
Dynamometer
LN2 storage
e
CO2 tube tank
py
Dry
Data
Co
acquisition
Amplifier
LN2
ot
tN
rip
Fig. 1
sc
nu
Cutting tool
Chip
Ma
Workpiece
ed
pt
ce
Hot point
Ac
Fig. 2
24

800
Maximum Temperature, T (ºC)
Dry LN2 CO2
700
Decrease, T (°C)
600
d
te
500
di
400
e
300
py
200
Co
0 50 100 150 200
Cutting Speed, Vc (m/min)
ot
Fig. 3
tN
fit_wave2
rip
fit_wave5
fit_wave4
sc
Dry LN2 CO2

800
nu
% 22
600
VBmax (µm)
% 59
Increase VBmax
Ma
400
% 34
% 57
ed
200
pt
0
ce
0 50 100 150 200 250 300

Ac
Fig. 4
25

1.0
Tool-Chip Contact Area, A (mm )
Dry LN2 CO2
2
0.8
d
% 17
te % 45
0.6
di
0.4
e
py
0.2
Co
0.0 Effect of cutting speed
0 50 100 150 200

ot
Fig. 5tN
rip
sc
nu
Ma
ed
pt
ce
Ac
Fig. 6
26

Dry
Dr CO2
CO LN
LN2
y 2 2
d
te
di
Plastic deformation
e
py
Co
Fig. 7
ot
tN
90
150 m/min
80
210 m/min
150 m/min
rip
70
210 m/min
Hardness (Rockwell C)
60
sc
Expected hardness
50 of the cutting tool
at cryogenic
nu
40 Expected hardness of the

machining cutting tool at dry
30 machining
Ma
20
10
ed
0
30 90 140 170 200 230 260 290 315 345 370 400 435 460 490 520 550 580 600 630 660 690 720 750 770
Temperature ( C)
pt
Fig. 8
ce
Ac
27

Thermal effect Effect of wear
d
te
e di
py
Co
Fig. 9
ot
tN
rip
Effect of wear
sc
nu
Ma
ed
Fig. 10
pt
ce
Ac
28

Effect of wear
d
te
e di
py
Fig. 11
Co
ot
tN
rip
sc
nu
(a) (b)
Fig. 12
Ma
ed
pt
ce
Ac
29

3
Material Removal Rate, MRR (mm /sec)
0 150
50 300
100 450
150 600
200
Specific cutting force, Ks (MPa) 3400

3200 Dry LN2 CO2
3000
d
2800
te
2600
di
2400
2200
e
2000
py
0 50 100 150 200
Co
Fig. 13
Dry LN2
ot CO2
tN
Vc =30 m/min Vc =90 m/min Vc =120 m/min Vc =150 m/min Vc =210 m/min
rip
sc
nu
Ma
ed
pt
ce
Ac
Fig. 14
30

Dry LN2 CO2

280
Chip Thickness (µm)

240
200
d
te
160
di
120
e
py
0 30 60 90 120 150 180 210 240
Co
Fig. 15
ot
tN
rip
sc
nu
Ma
ed
Fig. 16
pt
ce
Ac
31

350
Dry LN2 CO2 As Received
340
330
Microhardness (HV) 320
310
300
d
290
Softening
te
280
270
di
260
e
250
py
0 20 40 60 80 100 120 140 160
Depth beneath the surface (µm)
Fig. 17
Co
ot
tN
rip
sc
nu
Ma
ed
Fig. 18
pt
ce
Ac
32

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Journal of Manufacturing Science and Engineering.

Received June 26, 2018;

Cryogenic Machining of Titanium Ti-5553

machining also produced shorter chips as compared to dry machining.

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In recent years, titanium alloy Ti-5Al-5V-3Cr-0.5Fe (Ti-5553) has attracted the

conductivity, chemical reactivity, high strength at elevated temperatures and low

modulus of elasticity [5] make it difficult to machine [6].

cutting tool during machining as a result of a chemical reaction, an increased cutting

Thus, problems in cutting process need to be resolved. Consequently, an investigation of

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and develop appropriate approaches to optimize the machining process.

speeds. Indeed, at a reasonable temperature, a conventional coolant might still be used.

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researcher purposes and industrial applications.

In this study, extreme and applicable machining conditions were selected to be

minimum temperature is expected to occur during cryogenic cooling conditions. Thus,

surface integrity at both extreme conditions.

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integrity characteristics, such as microhardness and phase transformation.

°C, according to various references [23, 24].

30, 90, 120, 150 and 210 m/min, were utilized.

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The machining experiments were conducted under dry machining conditions

was measured using a Liberty LH 87 coordinate measurement machine. The

calibration [11]. An example of the measured temperature profile is shown in Figure 2.

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A Future-Tech FM-310e microhardness tester was used to measure the

machined surface and subsurface are potentially influenced by the generated

temperature because it may alter the microstructure of the material. In contrast to

approaches to eliminate the detrimental effects of high temperature because it has a

temperature around -196 ºC [18, 28].

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ºC when machining with the carbon dioxide coolant.

It should be noted that this temperature was the maximum recorded

compared to dry machining of the titanium Ti-5553 alloy.

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materials are important parameters to evaluate to determine the machining

and cryogenic cooling conditions is presented in Figure 4. No considerable difference in

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the lower cutting speed.

face as compared to a new and fresh tool.

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beyond did not seem to be applicable in machining of this alloy.

resistance and hardness at a certain temperature. According to the literature, the

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resistance of any material, as shown in the wear model below [31]:

hardness as a function of the temperature changes. This temperature is the maximum

difference in the tool wear that occurred during machining.

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liquid nitrogen-assisted cutting.

reduce the energy requirement to plastically deform the workpiece.

presented in Figures 10 and 11, respectively.

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caused the force requirement for permanent deformation to reduce approximately

10% increase in the force requirement.

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Chip breaking and thickness

Chip control is an important issue in many machining operations, particularly in

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minimum deviation was obtained from the liquid nitrogen-assisted machining

much higher dimensional accuracy.

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