department of mechanical engineering performance analysis

Department of Mechanical Engineering Performance Analysis Of Cryogenic Cooling On Turning Process

TKIET Warananagar

ACKNOWLEDGEMENT

We are greatly indebted to our guide Prof. P. R. Patil, for his unstinted support

and valuable suggestions. We are grateful to him not only for the guidance, but also for

unending patience and keeping our spirits high throughout project work. We express

sincere thanks to our beloved Head of the Department, Dr. A. S. Todkar and Principal,

Dr. S. V. Anekar for being source of inspiration and providing us the different facilities

to carry out work.

We extend deepest thanks to all the teaching and non teaching staff of the

Department of Mechanical Engineering of TKIET for their assistance and cooperation.

Finally, we would like to thank our parents and friends for their moral support and

encouragement throughout our academics.

Student Names Signature

Mr. Chaitanya Manikrao Babar

Mr. Akash Shahaji Patil

Mr. Sourabh Sanjay Patil

Mr. Vijay Sarjerao Patil

Mr. Vishwajeet Ishwara Patil


TKIET Warananagar

ABSTRACT

High production machining of steel inherently generate high cutting temperature, which

not only reduces tool life but also impairs the product quality. Conventional cutting fluids

are ineffective in controlling the high cutting temperature and rapid tool wear.

The present work deals with experimental investigation in the role of cryogenic cooling

by liquid nitrogen jet on tool wear and surface finish in plain turning of mild steel at

industrial speed-feed combination by HSS tool.

Cryogenic cooling is an environment friendly clean technology for desirable

control of cutting temperature.

Cryogenic cooling offers real advantages when compared to mechanical cooling.

These are the most important:

♦ Lower maintenance costs – fewer and less expensive parts to maintain

♦ Lower temperatures possible – down to –195°C

♦ Higher temperatures possible – up to 500°C

♦ Smaller and lighter equipment requires less space

♦ Less heat dissipated into the room

The results have been compared with dry machining and machining with soluble oil as

coolant. The results of the present work indicate substantial benefit of cryogenic cooling

on tool life and surface finish. This may be attributed to mainly reduction in cutting zone

temperature and favourable change in the chip-tool interaction. Further it was evident that

machining with soluble oil cooling failed to provide any significant improvement in tool

life, rather surface finish deteriorated.


TKIET Warananagar

TABLE OF CONTENTS

Sr.

No.

Chapter

No.

Name of the chapter

Page

No.

1 1 Introduction

9

2 2 Literature review

11-13

3 3 Problem definition and Objectives

15

4 4 Fabrication of Cryogenic cooling setup 17-23

5 5

5.1

5.2

5.3

5.4

Experimental work

Analysis of Material Removal Rate

Analysis of components on CMM

Analysis of chip morphology

Analysis of surface roughness

25

26-33

34-38

39-43

44-46

6

6

6.1

Conclusion

Cost Estimation

48

49

7 7 References 51-52


TKIET Warananagar

LIST OF FIGURES

Chapter

No.

Fig No.

Name of the figure

Page

No.

4 4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

Cryo Can Construction

Drafting of Cryo Can

Sealing Cap

Drafting of sealing cap

Pneumatic Pipe

Pneumatic Pipe Reducer

Nozzle

Compressor

Pressure reducing valve

Cryogenic cooling setup

17

18

19

20

21

21

22

22

23

23

5 5.1.1

5.1.2

5.1.3

5.1.4

5.1.5

Dry Turning Setup

Wet Turning Setup

Cryogenic Turning Setup

Speed Vs MRR Graph (0.5 DOC)

Speed Vs MRR Graph (0.75 DOC)

26

28

30

33

33


TKIET Warananagar

Chapter

No.

Fig No.

Name of the figure

Page

No.

5 5.2.1

5.4.1

5.4.2

5.4.3

CMM Machine

Ra, Rq value representation

Surface roughness tester

Roughness value graph

34

44

45

46


TKIET Warananagar

LIST OF TABLES

Chapter

No.

Table No.

Name of the table

Page

No.

5 5.1

5.1.1

5.1.2

5.1.3

5.1.4

5.1.5

5.1.6

5.2.1

5.2.2

5.2.3

5.2.4

5.4.1

5.4.2

5.4.3

Experiment specifications

Dry turning observations

Material removal rates (Dry)

Wet turning observations

Material removal rates (Wet)

Cryogenic turning observations

Material removal rates (Cryogenic)

CMM specifications

Dry turning CMM report

Wet turning CMM report

Cryogenic turning CMM report

Dry turning surface roughness values

Wet turning surface roughness values

Cryogenic turning surface roughness values

25

26

28

29

30

31

32

35

36

37

38

45

46

46

6 6.1

6.2

Comparative Analysis of Dry, Wet and Cryogenic

turning

Cost Estimation

48

49


TKIET Warananagar

NOMENCLATURE

AISI : American Iron and Steel Institute

MRR : Material Removal Rate

V : Speed

F : Feed

DOC : Depth of Cut

DIA : Diameter

CMM : Co-ordinate Measuring Machine

Mea : Mean

Nom : Nominal

Dev : Deviation

CYLCTY : Cylindricity

Ra, Rq, Rz : Roughness Values


TKIET Warananagar

CHAPTER ONE

INTRODUCTION


TKIET Warananagar

INTRODUCTION

The cooling applications in machining operations play a very important role and

many operations cannot be carried out efficiently without cooling. Application of a

coolant in a cutting process can increase tool life and dimensional accuracy, decrease

cutting temperatures, surface roughness and the amount of power consumed in a metal

cutting process and thus improve the productivity. In this review, liquid nitrogen, as a

cryogenic coolant, was investigated in detail in terms of application methods in material

removal operations and its effects on cutting tool and work piece material properties,

cutting temperature, tool wear/life, surface roughness and dimensional deviation, friction

and cutting forces. As a result, cryogenic cooling has been determined as one of the most

favourable method for material cutting operations due to being capable of considerable

improvement in tool life and surface finish through reduction in tool wear through control

of machining temperature desirably at the cutting zone.

In the first part of this work a comprehensive state-of-the-art literature study is

presented, with the main focus on turning operation. The second part of the essay covers

the experimental work where tests were performed in turning of mild steel under dry,

flood cooling and cryogenic cooling. The results revealed an advantage in the favour of

cryogenic cooling concerning precision and surface finish but an obvious need for further

optimization of the process was evident as well.


TKIET Warananagar

CHAPTER TWO

LITERATURE REVIEW


TKIET Warananagar

LITERATIRE REVIEW

1) Application of Cryogenic Coolants in Machining Processes

State-of-the-art Literature Study and Experimental Work on Metal Matrix Composite.

Trausti Stefánsson ,Master’s Thesis

Royal Institute of Technology School of Industrial Engineering and Management

Conventional cutting fluids are known for being expensive, polluting and a non-

sustainable part of modern manufacturing processes. Global industrial trends are leaning

towards environmental and health friendly technologies. Cryogenic cooling is an

innovative and sustainable method, capable of replacing conventional oil-based cutting

fluids under various conditions. The method has already proved to have a great potential

in many different machining setups, performing equally or better than conventional

cooling strategies in all criteria concerning machinability. Majority of research work

published about cryogenic machining has revolved around turning operations most

commonly in combination with steels, nickel-based alloys and titanium-based alloys.

2) Beneficial Effects of Cryogenic Cooling over Dry and Wet Machining

on Tool Wear and Surface Finish in Turning AISI 1060 Steel.

S. Paul*, N. R. Dhar and A. B. Chattopadhyay

Department of Mechanical Engineering

Indian Institute of Technology, Kharagpur.

High production machining of steel inherently generate high cutting temperature, which

not only reduces tool life but also impairs the product quality. Conventional

cutting fluids are ineffective in controlling the high cutting temperature and rapid tool

wear. Further they also deteriorate the working environment and lead to general

environmental pollution. Attempts have already been initiated to control the pollution


TKIET Warananagar

problem by cryogenic cooling which also helps in getting rid of recycling and disposal of

conventional fluids. The present work deals with experimental investigation in the role of

cryogenic cooling by liquid nitrogen jet on tool wear and surface finish in plain turning

The results have been compared with dry machining

and machining with soluble oil as coolant.

3) Role of cryogenic cooling in machining AISI 4320 steel.

N. R. Dhar1, S. Paul2 and A. B. Chattopadhyay

1. Assistant Professor, Technical Teacher=s Training College, Tejgaon Industrial Area,

Dhaka 1208, Bangladesh

2. Department of Mechanical Engineering, Indian Institute of Technology, Kharagpur,

West Bengal 721 302, India

Increase in cutting velocity and feed for machining with high productivity is generally

restricted by the elevated cutting temperature, which causes rapid tool failure. In

precision machining also, the major problem is the high cutting temperature, which

impairs the dimensional and form accuracy of the product, its surface integrity by

inducing tensile residual stresses and surface and subsurface cracks. Application of

conventional cutting fluid often cannot control the high cutting temperature in high

production machining. Besides, they are major source of pollution from machining

industries. Cryogenic cooling is an environment friendly clean technology for desirable

control of cutting temperature. The present work investigates the role of cryogenic

cooling by liquid nitrogen jet on average chip-tool interface temperature, tool wear,

dimensional accuracy and surface finish in turning AISI 4320 steel under industrial

speed-feed conditions.


TKIET Warananagar

4) Review on experimental analysis of cryogenic cooling on various

machining processes.

Tushar Anil Gholap1, Suprabhat .A. Mohod2 1Department Of Mechanical Engineering

Lokmanya Tilak College of Engineering, Koparkhirane, Navi Mumbai-400709, (India)

2Asst. Professor Department of Mechanical Engineering Lokmanya Tilak College of

Engineering, Koparkhirane, Navi Mumbai-400709, (India)

The word Cryogenics is originated from two Greek words, which are “Kayos” and

“Genes” respectively. The word “Kayos” means “Cold or freezing” and “Genes” is

nothing but “born or produced”. Generally Cryogenic concept is known for attaining or

obtaining very low temperatures and in this generally Liquid Nitrogen and Liquid

Oxygen are commonly used. Sometimes Liquid Helium is also used for Cryogenic

purposes. The temperature required to hold hydrogen and oxygen at liquid state are 20K

and 90K respectively. Cryogenic technology mainly refers to systematic study of

producing very low temperatures of below 120K and studying material’s behaviour and

properties at particular temperatures. In Era of Modern Engineering and Technology the

“Sustainable Manufacturing” is of prime importance. In the manufacturing processes,

machining of components results in tool wear due to increase in cutting tool temperature

and heat zone thereby deformation and destruction of work piece and cutting tool, finally

work piece and cutting tool both get damaged. To avoid above adverse effects of

machining, adoption of proper cooling technique is required. But conventional cooling

processes are unable to control all such adverse effects because of this cooling of

machined components by Cryogenic technique is growing demand in sector of

manufacturing and production.


TKIET Warananagar

CHAPTER THREE

PROBLEM DEFINITION

AND

OBJECTIVES


TKIET Warananagar

PROBLEM DEFINITION

High production machining of any alloy steel inherently generate high cutting

temperature, which not only reduces tool life but also impairs the product quality.

Conventional cutting fluids such as water based coolants are ineffective in controlling the

high cutting temperature and rapid tool wear. Further, they also deteriorate the working

environment and lead to general environmental pollution. Cryogenic cooling helps in

getting rid of recycling and disposal of conventional fluids.

OBJECTIVES

The objectives of the project work are as follows-

1) To improve the performance of machining processes by use of cryogenic coolant.

2) To increase the dimensional accuracy.

3) To decrease cutting temperatures and surface roughness in metal cutting process.

4) To improve material removal rate and minimize waste.

5) To reduce overall production cost.


TKIET Warananagar

CHAPTER FOUR

FABRICATION OF

CRYOGENIC COOLING SETUP


TKIET Warananagar

Fabrication Work

Liquid Nitrogen Storage Container

Fig no 4.1 : Cryo Can Construction


TKIET Warananagar

Fig no 4.2 : Drafting of Cryo Can

Specifications:

Manufacturer : Gemini Industrial Gases Incorp

Capacity : 3.9 liters

Material : Aluminium alloy

Glass coating : Borosilicate glass


TKIET Warananagar

Construction:

A cryogenic storage dewar is a specialised type of vacuum flask used for

storing cryogens (such as liquid nitrogen or liquid helium), whose boiling points are

much lower than room temperature. Cryogenic storage dewars may take several different

forms including open buckets, flasks with loose-fitting stoppers and self-pressurising

tanks. All dewars have walls constructed from two or more layers, with a

high vacuum maintained between the layers. This provides very good thermal

insulation between the interior and exterior of the dewar, which reduces the rate at which

the contents boil away. Precautions are taken in the design of dewars to safely manage

the gas which is released as the liquid slowly boils.

Sealing Cap :

Fig no 4.3 : Sealing Cap

https://en.wikipedia.org/wiki/Vacuum_flask

https://en.wikipedia.org/wiki/Cryogen

https://en.wikipedia.org/wiki/Liquid_nitrogen

https://en.wikipedia.org/wiki/Liquid_helium

https://en.wikipedia.org/wiki/Boiling_points

https://en.wikipedia.org/wiki/Room_temperature

https://en.wikipedia.org/wiki/Bucket

https://en.wikipedia.org/wiki/Vacuum

https://en.wikipedia.org/wiki/Thermal_insulation

https://en.wikipedia.org/wiki/Thermal_insulation


TKIET Warananagar

Fig no 4.4 : Drafting of sealing cap

Specification :

Material : Polyster Plastic

Extreme low water absorption, in particular comparison to Nylon (Polyamides)

Exceptional dimensional stability, due to the low water absorption.

Excellent electrical properties.

Excellent resistance to chemical attack and high environmental stress crack

resistance, in particular in comparison to polycarbonates, due to the semi-

crystalline nature of polyesters.

Very good heat and heat ageing resistance.

Very low creep, even at elevated temperatures.

Very good colour stability.

Excellent wear properties


TKIET Warananagar

Physical Properties :

Tensile Strength : 2.5 N/mm2

Thermal Coefficient of expansion : 70 × 10-6

Density : 1.37 gm/cm3

Pneumatic Pipe :

Thickness : 1.5mm

Outer diameter : 8mm and 10mm

Material : Polyurethane

Fig no 4.5 : Pneumatic Pipe

Pneumatic Pipe Reducer :

• Type: Push to Connect Fittings Straight

Union Reducer

• Material: Composite/Nickel Plated Brass

• Fluid Type: Air

• Tubing:12mm-10mm Fig no 4.6 : Pneumatic Pipe Reducer

• Pressure Range: 0-220 PSI/ 0-15 kgf/cm2

• Ambient/Fluid Temperature: 32-140° F/0-60° C


TKIET Warananagar

Nozzle :

Make : Vortech Nozzles and Jets.

Model : 1201 Nozzle

Features :

Compact size.

Can be permanently mounted on copper

tubing.

Can be bent, flared. Fig no 4.7 : Nozzle

Compressor :

Make : Mecco Engineering Company,

Coimbatore.

Model : MSC 10

Speed : 700 rpm

Working Pressure : 10 bar, 150 Psi. Fig no 4.8 : Compressor

Power : 2 HP

Tank Capacity : 160 Liter


TKIET Warananagar

Pneumatic Pressure Reducing Valve :

• Model : WGS

• Body : CF8 / CF8M

• Size : 1/2" to 4"

• Bonnet : CF8 / CF8M

• Seat : NBR / VITON Fig no 4.9 : Pressure Reducing Valve

• Temperature : 180 °C (For Air)

• Max Inlet Pressure : 21 BAR

• Pressure Adjusting Range : 1 ~ 6 BAR , 4 ~ 10 BAR

• End Connection : Screwed End / Flanged End 150 Class.

Experimental Setup Block Diagram:

Fig no 4.10 : Cryogenic cooling setup

PU Pipe

Polyester

cap

compressor Drier

Pressure

regulator

Pressure relief

valve

Nozzle


TKIET Warananagar

CHAPTER FIVE

EXPERIMENTAL WORK


TKIET Warananagar

METHODOLOGY

Mild steel bar of initial diameter 38 mm and length 130 mm was straight turned on Lathe

Machine by High Speed Steel tool by different speed-feed combination under dry machining, and

wet machining.Table-1 provides the detailed experimental conditions.

Table no 5.1 :- Experiment specifications

Machine tool Anil Lathe, 1.5KW, India

Work specimen material Mild Steel (C 0.16 to 0.18 %, Mn 0.70 to

0.90 %, Si 0.40%,S 0.04% ,P 0.04%)

Size Φ38 X 130 mm

Cutting tools High speed Steel

Working tool geometry 7-8-5-6-9-4-1

Process parameters

Cutting velocity ( Vc)

Feed rate (So)

Depth Of Cut

Speed

26 - 81 m/min

0.222, 0.126 ,0.073 mm/rev

0.5 and 0.75 mm

225,395,680 rpm

Environment Dry, Wet, Cryogenic


TKIET Warananagar

Chapter 5.1 : Analysis of material removal rate.

Experimental Setup for Dry Turning :

Fig no 5.1.1 : Dry Turning Setup

Dry turning observations :

Table no 5.1.1 : Dry turning observations

Sr.No DEPTH OF CUT SPEED REQUIRED OBTAINED VARIATION

mm Rpm mm mm mm

1 0.5 225 35 35.12 0.12

2 0.5 395 37.5 37.42 0.08

3 0.5 680 36.25 36.23 0.02

4 0.75 225 34.25 34.23 0.02

5 0.75 395 36.75 36.71 0.04

6 0.75 680 35.5 35.4 0.01


TKIET Warananagar

CALCULATIONS

MRR = V F d

V= Cutting speed (mm/min)

V= N Do π

Do = Original Diameter (mm)

N= Spindle speed

F = Feed (mm/rev)

d = Depth of cut (mm)

Sample calculation

For Dry Turning operation

N =395 rpm , d=0.5 mm

Do = 38 mm

V= N Do π

=395

=47155.30 mm/min

MRR = V F d

MRR =

0.5

MRR= 2984.51 mm3/min


TKIET Warananagar

Table no 5.1.2 : Material removal rates (Dry)

Sr.No DEPTH OF CUT SPEED TIME MRR

Mm rpm MIN mm3/min

1 0.5 225 2.1666 1946.22

2 0.5 395 3.9166 2626.45

3 0.5 680 2.75 2984.51

4 0.75 225 2.25 2896.23

5 0.75 395 3.6333 3939.67

6 0.75 680 2.6 4408.76

Experimental Setup for Wet Turning :

Fig no 5.1.2 : Wet Turning Setup


TKIET Warananagar

Wet turning observations :

Table no 5.1.3 : Wet turning observations :


Mm rpm Mm mm mm

1 0.5 225 35 34.85 0.15

2 0.5 395 37.5 37.35 0.05

3 0.5 680 36.25 36.15 0.1

4 0.75 225 34.25 34.18 0.07

5 0.75 395 36.75 36.7 0.05

6 0.75 680 35.5 35.35 0.05

Sample calculation

For wet Turning operation

N =395 rpm , d=0.75 mm

Do = 37.35 mm

V= N Do π

=395

=46348.70 mm/min

MRR = V F d

MRR =

0.75

MRR= 4400.083 mm3/min


TKIET Warananagar

Table no 5.1.4 : Material removal rates (Wet)


Mm Rpm MIN mm3/min

1 0.5 225 1.9166 1943.21

2 0.5 395 3.9161 2684.54

3 0.5 680 2.4166 2984.51

4 0.75 225 3.25 2900.56

5 0.75 395 2.5 4400.08

6 0.75 680 1.966 4476.76

Experimental Setup for Cryogenic Turning :

Fig no 5.1.3 : Cryogenic Turning Setup


TKIET Warananagar

Cryogenic turning observations :

Table no 5.1.5 : Cryogenic turning observations :


Mm rpm Mm Mm mm

1 0.5 225 32.8 32.66 0.14

2 0.5 395 38.1 38.1 0

3 0.5 680 35.6 35.6 0

4 0.75 225 31.1 31.04 0.06

5 0.75 395 36.6 36.6 0

6 0.75 680 34.1 33.8 0.3

Sample calculation

For cryogenic Turning operation

N =395 rpm , d=0.5 mm

Do = 38.1 mm

V= N Do π

=395

=47155 mm/min

MRR = V F d

MRR =

0.5

MRR= 2984.5130 mm3/min


TKIET Warananagar

Table no 5.1.6 : Material removal rates (Cryogenic)


Mm Rpm MIN mm3/min

1 0.5 225 1.9166 2565.1104

2 0.5 395 3.9161 2984.5130

3 0.5 680 2.4166 3100.456

4 0.75 225 3.25 3656.8138

5 0.75 395 2.5 4611.83

6 0.75 680 1.966 4881.96


TKIET Warananagar

Speed Vs MRR Graph for 0.5 DOC :

Fig no 5.1.4 : Speed Vs MRR Graph (0.5 DOC)

Speed Vs MRR Graph for 0.75 DOC :

Fig no 5.1.5 : Speed Vs MRR Graph (0.75 DOC)

1800

2000

2200

2400

2600

2800

3000

3200

0 200 400 600 800

MR

R

Speed

Speed Vs MRR

Dry

Flood

Cryo

1800

2300

2800

3300

3800

4300

4800

5300

0 100 200 300 400 500 600 700 800

MR

R

Speed

Speed Vs MRR

Dry

Flood

Cryo


TKIET Warananagar

Chapter 5.2 : Analysis of components on CMM.

Co-ordinate Measuring Machine (CMM) :-

Fig no 5.2.1 : CMM Machine


TKIET Warananagar

Specifications of CMM :

Table no 5.2.1 : CMM Specifications

Model 3-D CMM Spectra

Make Accurate Gauging & Instruments Pvt Ltd. Pune

Measuring Range

X axis : 500 mm

Y axis : 600 mm

Z axis : 400 mm

Resolution 0.5 micron

Accuracy 3.5 + L/250 micron

Probing System MH20i Manual Indexing Probe Head with Integral TP20

module

Calibration Sphere Diameter 30 mm (Ceramic)

Software Geometric Measuring Software, Accusoft +

Construction Bridge Type

Table Size 1230 × 770 × 850 mm (L × W × H)

Guide/ Bearing Air Bearing

Operation Manual


TKIET Warananagar

Analysis of component on CMM:

DRY TURNING:

Table no 5.2.2 : Dry turning CMM report

Ref Sys:

Mea Nom Dev

X 209.3983 209.3983 0

Y 39.7854 39.7854 0

Z 589.4582 589.4582 0

DIAM 34.18 34.18 0

CYLCTY 0.0181 0 0.0181

SIGMA 0.0111 0 0.0111

Mea Nom Dev

X 209.4494 209.4494 0

Y 39.8042 39.8042 0

Z 569.6601 569.6601 0

DIAM 36.564 36.564 0

CYLCTY 0.0252 0 0.0252

SIGMA 0.0155 0 0.0155

CONCEN 0.4105 0 0.4105


TKIET Warananagar

WET TURNING:

Table no 5.2.3 : Wet turning CMM report

Ref Sys:

MCS

Mea Nom Dev

X 167.1187 167.1187 0

Y 81.8162 81.8162 0

Z 581.0399 581.0399 0

DIAM 34.3318 34.3318 0

CYLCTY 0.0567 0 0.0567

SIGMA 0.0383 0 0.0383

Ref Sys:

MCS

Mea Nom Dev

X 167.1774 167.1774 0

Y 81.7879 81.7879 0

Z 541.4103 541.4103 0

DIAM 36.8799 36.8799 0

CYLCTY 0.0124 0 0.0124

SIGMA 0.0077 0 0.0077

CONCEN 0.1256 0 0.1256


TKIET Warananagar

Cryogenic turning :

Table no 5.2.4 : Cryogenic turning CMM report

Ref Sys:

MCS

Mea Nom Dev

X 220.7887 220.7887 0

Y 204.6207 204.6207 0

Z 580.0786 580.0786 0

DIAM 33.6803 33.6803 0

CYLCTY 0.0092 0 0.0092

SIGMA 0.0053 0 0.0053

Ref Sys:

MCS

Mea Nom Dev

X 220.7863 220.7863 0

Y 204.6341 204.6341 0

Z 548.2366 548.2366 0

DIAM 39.1288 39.1288 0

CYLCTY 0.0079 0 0.0079

SIGMA 0.0047 0 0.0047

CONCEN 0.0488 0 0.0488


TKIET Warananagar

Chapter 5.3 : Analysis of chip morphology.

Different types of chips of various shape, size, color etc. are produced by machining

depending upon

• Type of cut, i.e., continuous (turning, boring etc.) or intermittent cut (milling)

• Work material (brittle or ductile etc.)

• Cutting tool geometry (rake, cutting angles etc.)

• Levels of the cutting velocity and feed (low, medium or high)

• Cutting fluid (type of fluid and method of application)

The basic major types of chips and the conditions generally under which such types of

chips form are given below:

o Discontinuous type :

• Of irregular size and shape : - Work material – Brittle like grey cast iron

• Of regular size and shape : - Work material - Ductile but hard and work hardenable

- Feed – Large

- Tool rake – Negative

- Cutting fluid – Absent or Inadequate

o Continuous type

• Without BUE :

Work material – Ductile

Cutting velocity - High

Feed – Low

Rake angle - Positive and large


TKIET Warananagar

Cutting fluid – Both cooling and lubricating

• With BUE : -

Work material – Ductile

Cutting velocity – Medium

Feed – Medium or large

Cutting fluid – Inadequate or Absent.

Jointed or segmented type :

Work material – Semi ductile

Cutting velocity – Low to medium

Feed – Medium to large

Tool rake – Negative

Cutting fluid – absent


TKIET Warananagar

Dry turning Chip Morphology:

Speed=680 DOC=0.5 Speed=680 DOC=0.75




TKIET Warananagar

Wet turning chip morphology:





TKIET Warananagar

Cryogenic Turning Chip Morphology :





TKIET Warananagar

Chapter 5.4 : Analysis of surface roughness

Ra Value : The average roughness is the area between the roughness profile and its mean

line, or the integral of the absolute value of the roughness profile height over the

evaluation length.

Rq Value : Rq is the root mean square average of the profile heights over the evaluation

length.

Rz Value : Rz is the arithmetic mean value of the single roughness depths of consecutive

sampling lengths.

Fig no 5.4.1 : Ra, Rq value representation


TKIET Warananagar

Fig no 5.4.2 : Surface roughness tester

Specifications

Model : Mitutoyo SJ-210

Measuring Speed = 0.25 - 0.75 mm/s

Measuring Range = 360 µm

Stylus = diamond tip

No of sampling length = 1-10 mm

Calibration : Ra Calibration Average method upto 5 measurements available.

Observations :

Dry turning

Table no 5.4.1 : Dry turning surface roughness values

Ra (µm) Rq (µm) Rz (µm)

Small Cylinder 11.619 13.964 56.463

Big Cylinder 8.601 10.636 43.245


TKIET Warananagar

Wet turning :

Table no 5.4.2 : Wet turning surface roughness values


Small Cylinder 4.499 5.707 26.168

Big Cylinder 4.719 5.855 27.257

Cryogenic turning :

Table no 5.4.3 : Cryogenic turning surface roughness values


Small Cylinder 4.246 5.242 23.070

Big Cylinder 4.142 5.089 22.199

Roughness value Graph :

Fig no 5.4.3 : Roughness value graph

0

10

20

30

40

50

60

Ra Rq Rz

Ro

ugh

ne

ss v

alu

e (

µm

)

Roughness Value

Dry

Wet

Cryo


TKIET Warananagar

CHAPTER SIX

CONCLUSION


TKIET Warananagar

CONCLUSION

Concentricity in cryogenic turning improved by 88.11% compared to dry turning.

Cylindricity in cryogenic turning improved by 68.65% compared to dry turning.

Material removal rate in cryogenic turning is 10.71% more, compared to dry turning.

As the speed increases in case of dry, wet and cryogenic turning the Material removal

rate increases.

Higher spindle speed gives larger continuous chip.

When feed rate increases the width of chip decreases.

As the speed increases chip size also increases.

Table no 6.1 : Comparative Analysis of Dry, Wet and Cryogenic turning

Effect of cooling and

lubricant strategy

DRY Turning

WET Turning

(Emulsion)

Cryogenic

Turning

Cooling Poor Good Excellent

Lubrication Poor Excellent Poor

Chip Removal Good Good Excellent

Workpiece Cooling Poor Good Excellent


TKIET Warananagar

COST ESTIMATION

Table no 6.2 : Cost Estimation

Sr. No.

Equipment Name

Expected

Cost

1 Mild Steel Rod NIL

2 Liquid Nitrogen Cylinder (Rent + Deposit) 7000/-

3 PVC Pipe 200/-

4 Nozzle 500/-

5 Pneumatic pressure control valve 1500/-

6 Sealing Cap 2000/-

7 Liquid Nitrogen 700/-

8 Surface Roughness testing 400/-

9 Pneumatic accessories 200/-

Total 12500/-


TKIET Warananagar

PROJECT MEMBERS:

SR.NO NAME EXAM SEAT NO SIGNATURE

1 Akash S. Patil 21901

2 Chaitanya M. Babar 21912

3 Vijay S. Patil 21961

4 Sourabh S. Patil 21970

5 Vishwajeet I. Patil 21974


TKIET Warananagar

REFERANCES

Journals and Research papers

1. Increasing Energy Efficiency in Turning of Aerospace Materials with High-

Pressure Coolant Supply.

Tolga Caylia*, Fritz Klockeb, Benjamin Döbbelerc a,b,cLaboratory for Machine

Tools and Production Engineering (WZL) of RWTH Aachen University,

Steinbachstrasse 19, 52074 Aachen, Germany.

2. Machining of Tungsten Heavy Alloy under Cryogenic Environment

Srinivasa Rao Nandama U. Ravikiranb and A. Anand Rao

3. Metrics-based Sustainability Evaluation of Cryogenic Machining

Tao Lua, I.S. Jawahira.

4. Influence of coolant flow rate on tool life and wear development in

cryogenic and wet milling of Ti-6Al-4V.

M. Ibrahim Sadika, Simon Isaksonb, Amir Malakizadib, Lars Nyborgb

5. Surface integrity analysis when machining Inconel 718 with conventional

and cryogenic cooling.

A.Iturbe, E. Hormaetxe, A. Garay, P.J. Arrazola

6. Cryogenic high speed machining of cobalt chromium alloy

Alborz Shokrania*, Vimal Dhokiaa, Stephen T Newmana

7. Cryogenic machining of biomedical implant materials for improved

functional performance, life and sustainability

I.S. Jawahira*, D.A. Puleob, J. Schoopa


TKIET Warananagar

8. Beneficial Effects of Cryogenic Cooling over Dry and Wet Machining

on Tool Wear and Surface Finish in Turning AISI 1060 Steel

S. Paul, N. R. Dhar and A. B. Chattopadhyay

9. ROLE OF CRYOGENIC COOLING IN MACHINING AISI 4320 STEEL

N. R. Dhar1, S. Paul2 and A. B. Chattopadhyay2

10. Manufacturing processes by P.C. Sharma.

department of mechanical engineering performance analysis

Documents