department of mechanical engineering performance analysis
TRANSCRIPT
Department of Mechanical Engineering Performance Analysis Of Cryogenic Cooling On Turning Process
TKIET Warananagar Page 1
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
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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.
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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
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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
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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
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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
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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
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CHAPTER ONE
INTRODUCTION
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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.
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CHAPTER TWO
LITERATURE REVIEW
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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
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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.
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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.
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CHAPTER THREE
PROBLEM DEFINITION
AND
OBJECTIVES
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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.
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CHAPTER FOUR
FABRICATION OF
CRYOGENIC COOLING SETUP
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Fabrication Work
Liquid Nitrogen Storage Container
Fig no 4.1 : Cryo Can Construction
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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
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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
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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
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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
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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
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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
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CHAPTER FIVE
EXPERIMENTAL WORK
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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
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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
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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
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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
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Wet turning observations :
Table no 5.1.3 : Wet turning observations :
Sr.No DEPTH OF CUT SPEED REQUIRED OBTAINED VARIATION
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
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Table no 5.1.4 : Material removal rates (Wet)
Sr.No DEPTH OF CUT SPEED TIME MRR
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
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Cryogenic turning observations :
Table no 5.1.5 : Cryogenic turning observations :
Sr.No DEPTH OF CUT SPEED REQUIRED OBTAINED VARIATION
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
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Table no 5.1.6 : Material removal rates (Cryogenic)
Sr.No DEPTH OF CUT SPEED TIME MRR
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
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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
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Chapter 5.2 : Analysis of components on CMM.
Co-ordinate Measuring Machine (CMM) :-
Fig no 5.2.1 : CMM Machine
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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
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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
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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
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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
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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
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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
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Dry turning Chip Morphology:
Speed=680 DOC=0.5 Speed=680 DOC=0.75
Speed=395 DOC=0.5 Speed=395 DOC=0.75
Speed=225 DOC=0.5 Speed=225 DOC=0.75
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Wet turning chip morphology:
Speed=225 DOC=0.5 Speed=225 DOC=0.75
Speed=395 DOC=0.5 Speed=395 DOC=0.75
Speed=680 DOC=0.5 Speed=680 DOC=0.5
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Cryogenic Turning Chip Morphology :
Speed=680 DOC=0.5 Speed=680 DOC=0.75
Speed=395 DOC=0.5 Speed=395 DOC=0.75
Speed=225 DOC=0.5 Speed=225 DOC=0.75
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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
Department of Mechanical Engineering Performance Analysis Of Cryogenic Cooling On Turning Process
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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
Department of Mechanical Engineering Performance Analysis Of Cryogenic Cooling On Turning Process
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Wet turning :
Table no 5.4.2 : Wet turning surface roughness values
Ra (µm) Rq (µm) Rz (µm)
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
Ra (µm) Rq (µm) Rz (µm)
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
Department of Mechanical Engineering Performance Analysis Of Cryogenic Cooling On Turning Process
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CHAPTER SIX
CONCLUSION
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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
Department of Mechanical Engineering Performance Analysis Of Cryogenic Cooling On Turning Process
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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/-
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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
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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
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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.