Titanium alloys are used in various industries due to their superior mechanical strength and corrosion resistance. However, titanium is classified as a difficult-to-machine material due to its low thermal conductivity that consequently causes poor tool life. In this study, cryogenic+MQL milling was performed to improve the machinability of Ti-6Al-4V; a cryogenic coolant and a minimum quantity fluid were sprayed simultaneously. The machinability was analyzed according to the cooling and lubrication conditions, focusing on the cutting force and tool wear. When the minimum quantity fluid was injected using two nozzles during cryogenic machining, the cutting force remained low despite the increase in machining distance due to the effective lubrication. The average cutting force at the long machining distances (82-86 passes) was 14.8% lower than that under the wet condition. The tool wear progressed without chipping, and the flank wear length was 55.5% lower than that of the wet machining because the cryogenic cooling and minimum quantity lubrication reduced the tool temperature, friction, and thermal shock.
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Design and Development of a Real-Time AI-Based Tool Failure Prediction System for Machining Difficult-to-Cut Materials Mi-Ru Kim, Hoon-Hee Lee, Min-Suk Park, Wang-Ho Yun Journal of the Korean Society of Manufacturing Technology Engineers.2025; 34(4): 225. CrossRef
Compacted graphite iron (CGI) has been widely used in the automobile industry because of its good mechanical properties. CGI has better strength as compared to grey iron due to its internal structure. It includes graphite particles, which enhance the adhesion between graphite and iron. However, the material characteristics can negatively affect the machinability. In this study, cryogenic milling was performed for CGI450. It is well known that cryogenic machining is effective in improving the machinability. The process included spraying liquid nitrogen as a cryogenic coolant, and the influences on machinability were experimentally investigated with a focus on the cutting force and surface roughness. When liquid nitrogen was sprayed, the cutting force was slightly increased due to the cold-strengthening effect. On the other hand, surface roughness was dramatically decreased by 44.7% as compared to dry milling because brittleness of work material was increased by cryogenic coolant spraying.
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The tungsten carbide is a material with high hardness, wear resistance, good chemical stability, and dimensional stability. Because of these characteristics, it is mainly used as a tool for cutting and molding such as molds, and casts required for manufacturing high value-added equipment such as automobile parts and medical equipment. However, it is difficult to process with the traditional machining methods because of the high toughness and hardness. To overcome these problems, a study of tungsten carbide machining processing using the ultrafast-laser was recently conducted. In this paper, the ultrafast lasers with the pulse duration of 190 fs, 5 and 10 ps, respectively, were used. When the experiments were conducted with pulse widths of 5 and 10 ps, respectively, micro-cracks were observed from the heat generated by the overlap of the laser pulses. Conversely, the machining processing using a laser with the pulse width of 190 fs showed a major advantage with no crack by minimizing the thermal effects.
Lightweight parts are necessary to improve fuel efficiency and reduce environmental impacts in transportation industry. As a result, there has been a shift away from using conventional metals toward using lighter materials with superior mechanical strength. These new materials typically include titanium alloys, nickel alloys, carbon fiber reinforced plastics (CFRPs), and CFRP-metal stacks, which are classified as advanced materials. However, due to the unique properties of these materials (e.g., high strength, low thermal conductivity, carbon fiber-induced hardness, etc.), the cutting process can be difficult. As a result, various manufacturing issues can occur during the cutting process, such as high tool wear, surface quality deterioration, delamination of the CFRP layer, fiber pull-out, and thermal deformation. In this paper, difficult-to-cut advanced materials were reviewed with regard to the influence of the physical properties of the materials and various defect issues that can occur during the mechanical cutting process. In addition, various approaches to improve the cutting process are introduced, including protecting tools with coatings, altering tool features, using high pressure or cryogenic cooling, extending tool life via ultrasonic vibration machining, and improving product quality and machinability.
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