CONTENTS

Chapter

Page

Contents

Acknowledgement

ii

Abstract

iii

List of figures

iv

List of table

Nomenclature

vi

1. Introduction

2. Objectives

3. Cryogenic Cooling

4.

3.1 Heat Generation in Machining Process

3.2 Tool Wears

3.3 Conventional cutting fluids

3.4 Drawbacks of conventional cutting fluids

Cryogenic cooling approaches

4.1 Cryogenic Pre-cooling the Work piece

4.2. Indirect Cryogenic cooling

10

4.3. Cryogenic spraying and jet cooling

11

4.4. Cryogenic Treatment

13

5.

Experimental setup

14

6.

Results and discussion

6.1. On cutting temperature

16

6.2. On cutting tool wear

17

6.3. On surface finish

20

6.4. On dimensional accuracy

21

7.

Conclusion

23

8.

Reference

24

ACKNOWLEDGEMENT

The elation and gratification of this seminar will be incomplete without

mentioning all the people who helped me to make it possible, whose gratitude
and encouragement were invaluable to me. Firstly I would like to thank god, for
bestowing his blessings upon me in my entire endeavor.
I express my sincere gratitude to Mr.Anfas Mukram T, Head of the
Department for his support and guidance. I like to thank Mr. Diljit A.R.,
(Lecturer), Mr. Abdul Muneer M (Assistant professor) for their valuable words
of advice. I am also thankful to all the other lectures in our department and
students of my class for their support and suggestions.

ii

ABSTRACT
High production machining at high cutting velocity and feed generates large amount of
heat and high cutting temperature, which shortens the tool life and deteriorates the job
quality. This problem becomes more acute when the jobs are made of high strength
materials and are difficult to machine. The conventional cutting fluids are not that
effective in such high production machining particularly in continuous cutting of
materials like steels. Further, the conventional cutting fluids are not environment friendly.
The major needs in machining are high material removal rate, good work surface finish
and low tool wear. In this paper, instead of conventional coolants, liquid nitrogen is
applied through specialized nozzles, so that liquid nitrogen can be directly enter to the
machining zone during the machining of stainless steel with carbide tools. Cryogenic
cooling in machining process is studied by machining AISI 4140 using steel carbide
inserts of two different integrated chip breaker geometry under dry machining and
cryogenic cooling. The effect of cryogenic cooling on cutting temperature, tool wear and
tool life, surface finish and dimensional accuracy is analyzed. The encouraging results
include significant reduction in tool wear rate, dimensional inaccuracy and surface
roughness by cryogenic cooling application mainly through reduction in the cutting zone
temperature and favorable change in the chiptool and worktool interaction. It was
found that tool life increases by applying liquid nitrogen using the modified tool.

iii

LIST OF FIGURES
Figure

Page

1.

Heat generation zones in orthogonal cutting

2.

Diagram of worn cutting tool, showing the principal

locations and types of wear that occurs

3.

Cryogenic work piece pre-cooling

9

4.

Application of LN2 to tool back

5.

Schematic

10
diagram

of

LN2

nozzle

system

11
6.
7.

Schematic diagram of cryogenic cooling setup

Variation in average chip-tool interface
temperature with Vc under dry and cryogenic cooling

8.

16

Growth of average flank wear, VB under dry and

cryogenic cooling

9.

15

18

Growth of average auxiliary flank wear,

VS under dry and cryogenic cooling

18

10. SEM view of worn out tip of insert under dry and
cryogenic cooling

20

11. Surface roughness value, Ra with time under dry

and cryogenic cooling

21

12. Variation in diameter with cutting length under dry

and cryogenic cooling

22

iv

LIST OF TABLE
Tables

Page

1. Experimental conditions

10

NOMENCLATURE

LN2

Liquid Nitrogen

BUE

Build Up Edge

SEM

Scanning Electron Microscope

Vc

Cutting Velocity

So

Feed Rate

VB

Principal Flank Wear

VS

Auxiliary Flank Wear

vi