Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool
The application of conventional cooling lubricants for the tribological conditioning of machining processes involves high additional costs and health risks. The application of a cryogenic carbon dioxide (CO<sub>2</sub>) snow cooling strategy is an economical and environmentally sound alt...
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| Format: | Article |
| Language: | English |
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MDPI AG
2019-01-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/3/1/15 |
| _version_ | 1819169652197031936 |
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| author | Thomas Heep Christian Bickert Eberhard Abele |
| author_facet | Thomas Heep Christian Bickert Eberhard Abele |
| author_sort | Thomas Heep |
| collection | DOAJ |
| description | The application of conventional cooling lubricants for the tribological conditioning of machining processes involves high additional costs and health risks. The application of a cryogenic carbon dioxide (CO<sub>2</sub>) snow cooling strategy is an economical and environmentally sound alternative for oily cooling emulsions since it has a high cooling effect as well as a residue-free sublimation. This article introduces a laser additive manufactured tool holder with an integrated dual nozzle which enables CO<sub>2</sub>-snow jet application. Initially this work focuses on the characterization and the selection of a suitable nozzle geometry. The modular tool body features an adapted channel structure for process-reliable and targeted CO<sub>2</sub>-snow cooling for turning processes. This enables the simultaneous cooling of the rake and flank face with CO<sub>2</sub>-snow, as well as the application of cryogenic multi-component cooling of the rake face. In the context of this study, the focus lies on the technological evaluation of three different supply strategies during the continuous turning of compacted graphite iron CGI-450 at increased cutting speed. It was established that an efficient rake face cooling is indispensable to achieve a low thermal tool load, and thus lower crater wear behavior. Therefore, this study contributes to an improvement in cryogenic machining processes regarding the design of additively manufactured tool bodies for process-reliable CO<sub>2</sub>-snow cooling, as well as for the selection of supply strategies to minimize the thermomechanical tool load. |
| first_indexed | 2024-12-22T19:22:54Z |
| format | Article |
| id | doaj.art-dbd4dd0ce9114aaab03e8aed485a2b76 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-12-22T19:22:54Z |
| publishDate | 2019-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-dbd4dd0ce9114aaab03e8aed485a2b762022-12-21T18:15:20ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942019-01-01311510.3390/jmmp3010015jmmp3010015Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning ToolThomas Heep0Christian Bickert1Eberhard Abele2Institute of Production Management, Technology and Machine Tools (PTW), Technical University of Darmstadt, 64287 Darmstadt, GermanyInstitute of Production Management, Technology and Machine Tools (PTW), Technical University of Darmstadt, 64287 Darmstadt, GermanyInstitute of Production Management, Technology and Machine Tools (PTW), Technical University of Darmstadt, 64287 Darmstadt, GermanyThe application of conventional cooling lubricants for the tribological conditioning of machining processes involves high additional costs and health risks. The application of a cryogenic carbon dioxide (CO<sub>2</sub>) snow cooling strategy is an economical and environmentally sound alternative for oily cooling emulsions since it has a high cooling effect as well as a residue-free sublimation. This article introduces a laser additive manufactured tool holder with an integrated dual nozzle which enables CO<sub>2</sub>-snow jet application. Initially this work focuses on the characterization and the selection of a suitable nozzle geometry. The modular tool body features an adapted channel structure for process-reliable and targeted CO<sub>2</sub>-snow cooling for turning processes. This enables the simultaneous cooling of the rake and flank face with CO<sub>2</sub>-snow, as well as the application of cryogenic multi-component cooling of the rake face. In the context of this study, the focus lies on the technological evaluation of three different supply strategies during the continuous turning of compacted graphite iron CGI-450 at increased cutting speed. It was established that an efficient rake face cooling is indispensable to achieve a low thermal tool load, and thus lower crater wear behavior. Therefore, this study contributes to an improvement in cryogenic machining processes regarding the design of additively manufactured tool bodies for process-reliable CO<sub>2</sub>-snow cooling, as well as for the selection of supply strategies to minimize the thermomechanical tool load.https://www.mdpi.com/2504-4494/3/1/15additively manufactured toolscarbon dioxide coolingCGI machining |
| spellingShingle | Thomas Heep Christian Bickert Eberhard Abele Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool Journal of Manufacturing and Materials Processing additively manufactured tools carbon dioxide cooling CGI machining |
| title | Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool |
| title_full | Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool |
| title_fullStr | Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool |
| title_full_unstemmed | Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool |
| title_short | Application of Carbon Dioxide Snow in Machining of CGI using an Additively Manufactured Turning Tool |
| title_sort | application of carbon dioxide snow in machining of cgi using an additively manufactured turning tool |
| topic | additively manufactured tools carbon dioxide cooling CGI machining |
| url | https://www.mdpi.com/2504-4494/3/1/15 |
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