Abstract

In titanium alloy machining, a large amount of heat is produced because of the intrinsic characteristics that raise the cutting temperature. In this study, a cooling method known as vortex tube cooling system (VTCS) is used along with carbon dioxide gas coolant to minimize the cutting temperature in Ti-6Al-4V machining. Initially, the optimum value of cold fraction was obtained by considering temperature drop, coefficient of performance, and isentropic efficiency (ηis) at constant coolant pressure. Further, the coolant temperature in the vortex tube varies from room temperature to a steady value that depends on coolant pressure and cold fraction. The trend of cutting temperature and cutting force with change in temperature of coolant and time was analyzed. Cutting force, cutting temperature, and surface roughness were analyzed under different cooling mediums such as dry air, compressed air, cool compressed air cooling (air with vortex tube), and VTCS at constant machining conditions (speed, feed, and depth of cut). From the experimental results, the least cutting temperature and surface roughness were reported under VTCS and the lowest cutting force under dry cutting.

Issue Section:
Technical Papers
Keywords:
dry cutting, compressed air cooling, vortex tube, Ti-6Al-4V, CO2 gas

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