A hybrid modeling approach based on computational fluid dynamics (CFD) and finite element method (FEM) is presented to simulate and study cryogenic machining (CM) of Ti–6Al–4V alloy. CFD analysis was carried out to study the characteristics of the fluid flow and heat transfer process of liquid nitrogen (LN2) jet used as a coolant in turning operation. The velocity, turbulence, gas volume fraction, and temperature of the impingement jet were investigated. Based on the analysis results, the coefficient of heat transfer (CHT) between the LN2 and cutting tool/insert was obtained and used in the FEM analysis to model the heat transfer process between the LN2 and the tool/chip/workpiece. A three-dimensional (3D) finite element (FE) model was developed to simulate a real CM operation. CM tests were carried out to validate the 3D FE model by comparing cutting forces and chip temperature. To evaluate LN2 cooling effect on tool temperature and tool wear, a two-dimensional (2D) FE model was developed for steady-state thermal analysis of cryogenic and dry machining. Based on the predicted temperatures, the tool wear was estimated, showing that LN2 cooling can significantly improve tool life.
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February 2019
Research-Article
A Hybrid Modeling Approach for Characterization and Simulation of Cryogenic Machining of Ti–6Al–4V Alloy
Bin Shi,
Bin Shi
Aerospace Manufacturing
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Bin.Shi@cnrc-nrc.gc.ca
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Bin.Shi@cnrc-nrc.gc.ca
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Ahmed Elsayed,
Ahmed Elsayed
Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mail: Ahmed.Korashy@mail.mcgill.ca
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mail: Ahmed.Korashy@mail.mcgill.ca
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Ahmed Damir,
Ahmed Damir
Aerospace Manufacturing
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Ahmed.Damir@cnrc-nrc.gc.ca
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Ahmed.Damir@cnrc-nrc.gc.ca
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Helmi Attia,
Helmi Attia
Aerospace Manufacturing Technology Centre
(AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada;
(AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada;
Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mails: Helmi.Attia@ cnrc-nrc.gc.ca;
Helmi.Attia@mcgill.ca
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mails: Helmi.Attia@ cnrc-nrc.gc.ca;
Helmi.Attia@mcgill.ca
Search for other works by this author on:
Rachid M'Saoubi
Rachid M'Saoubi
Materials and Technology Development,
Seco Tools AB,
Springfield Business Park,
Alcester B49 6PU, Warwickshire, UK
e-mail: Rachid.Msaoubi@secotools.com
Seco Tools AB,
Springfield Business Park,
Alcester B49 6PU, Warwickshire, UK
e-mail: Rachid.Msaoubi@secotools.com
Search for other works by this author on:
Bin Shi
Aerospace Manufacturing
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Bin.Shi@cnrc-nrc.gc.ca
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Bin.Shi@cnrc-nrc.gc.ca
Ahmed Elsayed
Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mail: Ahmed.Korashy@mail.mcgill.ca
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mail: Ahmed.Korashy@mail.mcgill.ca
Ahmed Damir
Aerospace Manufacturing
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Ahmed.Damir@cnrc-nrc.gc.ca
Technology Centre (AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada
e-mail: Ahmed.Damir@cnrc-nrc.gc.ca
Helmi Attia
Aerospace Manufacturing Technology Centre
(AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada;
(AMTC),
National Research Council Canada (NRC),
5145 Avenue Decelles,
Montreal, QC H3T 2B2, Canada;
Department of Mechanical Engineering,
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mails: Helmi.Attia@ cnrc-nrc.gc.ca;
Helmi.Attia@mcgill.ca
McGill University,
817 Sherbrooke Street West,
Montreal, QC H3A 2K6, Canada
e-mails: Helmi.Attia@ cnrc-nrc.gc.ca;
Helmi.Attia@mcgill.ca
Rachid M'Saoubi
Materials and Technology Development,
Seco Tools AB,
Springfield Business Park,
Alcester B49 6PU, Warwickshire, UK
e-mail: Rachid.Msaoubi@secotools.com
Seco Tools AB,
Springfield Business Park,
Alcester B49 6PU, Warwickshire, UK
e-mail: Rachid.Msaoubi@secotools.com
1Corresponding author.
Manuscript received April 30, 2018; final manuscript received December 14, 2018; published online January 4, 2019. Assoc. Editor: Karl R. Haapala.
J. Manuf. Sci. Eng. Feb 2019, 141(2): 021021 (8 pages)
Published Online: January 4, 2019
Article history
Received:
April 30, 2018
Revised:
December 14, 2018
Citation
Shi, B., Elsayed, A., Damir, A., Attia, H., and M'Saoubi, R. (January 4, 2019). "A Hybrid Modeling Approach for Characterization and Simulation of Cryogenic Machining of Ti–6Al–4V Alloy." ASME. J. Manuf. Sci. Eng. February 2019; 141(2): 021021. https://doi.org/10.1115/1.4042307
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