effect of direct and indirect cryogen application methods on ...chetan 1*, bikash chandra behera 2,...
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![Page 1: Effect of Direct and Indirect Cryogen Application Methods on ...Chetan 1*, Bikash Chandra Behera 2, Sudarsan Ghosh 3, P Venkateswara Rao 4 1* Department of Mechanical Engineering,](https://reader034.vdocuments.site/reader034/viewer/2022043006/5f8ef876d502f803b43b4499/html5/thumbnails/1.jpg)
5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014, IIT
Guwahati, Assam, India
108-1
Effect of Direct and Indirect Cryogen Application Methods on the Turning
Forces, Tool Wear and Surface Finish of a Nickel Based Alloy (Nimonic 90)
Chetan1*, Bikash Chandra Behera2, Sudarsan Ghosh3, P Venkateswara Rao4
1*Department of Mechanical Engineering, IIT Delhi, 110016, [email protected]: 2 Department of Mechanical Engineering, IIT Delhi, 110016, [email protected]:
3Department of Mechanical Engineering, IIT Delhi, 110016, [email protected]: 4Department of Mechanical Engineering, IIT Delhi, 110016, [email protected]:
Abstract
Due to the stricter environment legislation and also due to an increase in the occupational diseases amongst the
workers, it is necessary for the manufacturing sector to shift towards sustainable production techniques. Many
researchers have reported that the application of Cryogen in metal cutting could improve the machinability of some
materials without any ill effects on environment and health of workers. In machining, Cryogen can be used in two
ways: (a) direct method and (b) indirect method. In direct cryogen application method, cryogenic gas from a suitably
designed nozzle is directly applied to the tool-chip interface. While in indirect cryogen application cryogenic
treatment is done on the cutting tool which may be subjected to a temperature below 0 ͦC for a prolonged duration of
time. This paper presents the comparison between the direct and indirect cryogen application methods during
machining of Nimonic 90, a widely used nickel based super alloy. The measurement of Tool wear, surface
roughness and cutting forces has been carried out for both these methods to determine the more effective method
which can be used successfully during machining of the alloy. Keywords: Cryogenic cooling, Cryogenic treatment, Machinability, Nimonic, Sustainability
1 Introduction Machining is one of the most widely used
manufacturing operation all over the world. It has been
estimated that machining contributes towards 5% GDP
in developed world (Jayal et al., 2010). On the other
hand, it has also been noticed that machining operation
has detrimental effects on surrounding environment and
workers health (Marksberry, 2007). In order to make
machining operations more ecologically viable and
environmental friendly, it is necessary to introduce
sustainability in it. Sustainability in metal cutting
process can serve many benefits such as: 1) reduction in
overall cost, 2) reduction in power consumption, 3)
reduction in wastage, and 4) enhanced operational
safety. Several sustainable techniques like dry cutting,
cryogenic cooling (direct or indirect application),
minimum quantity lubrication (MQL) and compressed
air cooling have been evolved in recent years to make
machining process more cleaner and greener (Sharma et
al., 2009). Many difficult to machine materials like
Inconel 718 and Ti6Al4V based alloys have been
machined successfully using sustainable techniques
(Ezugwu et al., 2003). Nimonic is another important
nickel based alloy which is being widely used in
automobile, aerospace, marine and locomotive industry.
Despite of its poor machinability, very few literatures
are available about the machining characteristics of
Nimonic alloys.
2 Literature review
2.1 Sustainable machining techniques In machining operation it’s mandatory to use
cutting fluids or metal working fluids (MWFs) for
enhancing life of cutting tool and surface integrity of
work piece. It is an estimate that 16% of the total
manufacturing cost is associated with these MWFs
(Abele and Frohlich, 2008). The use of metal working
fluids is a biggest problem for manufacturing sector
because these are considered to be potential sources of
air and water pollution. These cutting fluids are also
cause of many respiration and skin related problems
amongst the workers. In order to eradicate these
problems, sustainable techniques like dry cutting,
cryogenic processing and cryogenic cooling are found
to be promising options (Lawal et al., 2013).
2.2 Dry cutting
In this process machining is performed in the
absence of pollution causing cutting fluids. Dixit et al.
(2012) suggested many advantages of dry cutting as
listed below
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Effect of Direct and Indirect Cryogen Application Methods on the Turning Forces, Tool Wear and Surface Finish of a Nickel Based Alloy
(Nimonic 90)
108-2
• The problems like water and soil
contamination are absent in dry machining.
• No extra chemical treatment is required for
cleaning dry waste like swarfs and chips. The
solid waste can directly used for recycling
purpose.
• It also cut down the cost associated with
coolant thereby makes machining process more
economic.
• Dry machining also helps in improving tool
life in certain intermittent machining
operations like milling process.
Spur and Lachmund (1995) used CBN and ceramic
tools for machining of cast iron. They have concluded
that CBN tools are best suited for machining of cast iron
due their high thermal conductivity. Devillez et al.
(2007) tried machining of Inconel 718 with coated and
uncoated tools under dry mode. The magnitudes of
cutting and feed force were found to be more in
uncoated tools in comparison to coated tools. They
concluded that machinability of this alloy can further be
improved by doing nano structured coating on cutting
inserts. The methods such as: Surface texturing on
cutting tool, machining with solid lubricants and
minimum quantity lubrication can also be employed to
further enhance the sustainability of dry turning process.
2.3 Cryogenic processing
Cryogenic processing is the treatment of cutting tools
below 0 °C to enhance its mechanical properties. This is
an indirect cryogenic method in which various gases
such as CO2, nitrogen and helium are used in liquefied
form. Soaking temperature, cooling rate and tempering
rate are the main parameters considered during
cryogenic treatment. These terms have their usual
meaning as given below
• Soaking temperature: Temperature at which
specimen has to be placed for prolonged period.
• Cooling rate: Rate of change of temperature from
room temperature to soaking temperature.
• Tempering rate: rate of change of temperature from
soaking temperature to cooling temperature.
Many researcher have carried out this subzero treatment
on various tool steels by varying these important
parameters. Mohan Lal et al. (2001) have cryogenically
treated T1, M2 and D3 type tool steels. They have
achieved 110% increase in the tool life of T1 tool
followed by M2 and D3 tool steels. Meng et al. (1994)
have shown an increase of 600 % in the wear resistance
of tool steel by cryogenic processing. Recently, Gill et
al. (2011) carried out shallow (-110 °C) and deep (-196
°C) treatment of coated carbide tool. They were
successful in achieving 24% and 20% increase in the
tool life of shallow and deep treated tools respectively
during machining of C-65 steel.
2.4 Cryogenic cooling
This is also known as a direct method of cryogenic
application in which the jet of liquid nitrogen is applied
directly to the cutting zone. Many researchers have
achieved increase in tool life with the help of cryogenic
cooling. Cooling with cryogen not only removes heat
from cutting zone but also reduces the coefficient of
friction by making lubricating cushion between chip-
tool interface. Recently, Kaynak (2014) performed the
machining of Inconel 718 under dry, MQL and
cryogenic conditions. The temperature reduction of 50%
and 25% is achieved with cryogenic cooling as compare
to both dry and MQL conditions respectively. Similarly,
significant reduction in the amount of flank wear and
radial forces is obtained in cryogenic condition in
comparison to other conditions. Likewise,
Dhananchezian and Kumar (2011) have performed
machining of Ti6Al4V under cryogenic and wet
conditions. They have achieved a reduction of 35% in
surface roughness with cryogenic machining over wet
machining. The cryogenic cooling also helped in
reducing cutting forces, cutting temperature and tool
wear over wet machining.
2.5 Machining of Nimonic alloy
Nimonic alloys are widely used in making turbine
blades, hot working tools, high temperature springs,
exhaust valves, shafts, turbine rings and many other
high temperature resisting components. Ezugwu et al.
(2004) carried out machining of Nimonic C-263 alloy
with coated carbide tools using coolant of various
concentrations (3%, 6% and 9%). 3% coolant
concentration worked best at lower cutting speeds of 68
and 85 m/min for improving tool life. At higher cutting
speed of 136 m/min, 6% coolant concentration gave
best results followed by 9% and 3% coolant
concentrations. Recently during dry cutting of Nimonic
C-263 alloy, it has been observed that both feed rate and
depth of cut significantly influence the surface finish,
tool wear and cutting forces in comparison to cutting
speed (Ezilarasan et al., 2013).
Though Nimonic is an important alloy but very few
literatures are available regarding its machining. So, this
work is an attempt to gather more information regarding
machining characteristics of this alloy using sustainable
techniques.
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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12
Guwahati, Assam, India
3 Experimental details
3.1 Workpiece Material
Nimonic 90 (UNS N07090) is nickel
cobalt based high temperature resistance super alloy.
This alloy is quite popular in aerospace industry because
of its high strength to weight ratio and high creep
resistance up to 920 °C. In the present study Nim
bar of 60 mm diameter and 300 mm length
used. The average micro hardness of this alloy was
found to be 445 HV, measured according
384-89 standard. Composition of this alloy has been
confirmed with the help of EDAX analysis
result of which is given in table 1.
Table 1: Chemical composition of Nimonic 90
Element Ni Cr Co
% 57.58 19.32 17.62
3.2 Cutting tool
Uncoated carbide inserts with sp
CNMG12408-THM-F have been used for carrying out
turning experiments. EDAX analysis of cutting tool was
also performed to know about its main constituent.
tool inserts consist of mainly tungsten, carbon and
cobalt (binder) listed in table 2.
Table 2: Composition of cutting inse
Element W C
% 84.61 8.39
3.3 Cryogenic treatment of cutting tool
(Indirect cryogenic application)
Cryogenic treatment enhances the wear
and hot hardness of cutting tool. To achieve this,
cryogenic treatment of carbide tools has been carried
out under controlled environment as shown in F
The cutting tools were kept at -
temperature for duration of eight hours. These inserts
were cooled from room temperature to soakin
temperature at a cooling rate of 2 °C/min. In order to
avoid thermal cracking the inserts were brought back to
room temperature at a heating rate of 1 °
in Figure 2.
All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12
Nimonic 90 (UNS N07090) is nickel-chromium-
cobalt based high temperature resistance super alloy.
This alloy is quite popular in aerospace industry because
of its high strength to weight ratio and high creep
C. In the present study Nimonic 90
and 300 mm length has been
average micro hardness of this alloy was
found to be 445 HV, measured according to ASTM-
89 standard. Composition of this alloy has been
the help of EDAX analysis and the
Nimonic 90 alloy
Ti Al
2.21 1.32
inserts with specifications
used for carrying out
EDAX analysis of cutting tool was
performed to know about its main constituent. The
tool inserts consist of mainly tungsten, carbon and
omposition of cutting insert
C Co
8.39 7.00
Cryogenic treatment of cutting tool
(Indirect cryogenic application)
Cryogenic treatment enhances the wear resistance
of cutting tool. To achieve this, deep
cryogenic treatment of carbide tools has been carried
as shown in Figure 1.
-196 °C soaking
temperature for duration of eight hours. These inserts
were cooled from room temperature to soaking
C/min. In order to
avoid thermal cracking the inserts were brought back to
erature at a heating rate of 1 °C/min as shown
Figure 1: Cryogenic treatment set
Figure 2: Cryogenic treatment
Many authors claimed that cryo-treatment of cutting
inserts leads to the precipitation of hard eta phase
particles. To confirm this claim, specimen of treated and
untreated carbide inserts has been prepared for
microstructure identification. ASTM B 6
procedures for the cemented carbides has been followed
to check any modification in the microstructure due to
sub zero treatment. Figure 3 revealed
between the microstructure of untreated and treated
inserts. Dense distribution of black
has been found in treated insert as compared to
untreated insert.
All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014, IIT
108-3
Cryogenic treatment set-up
Figure 2: Cryogenic treatment cycle
treatment of cutting
inserts leads to the precipitation of hard eta phase
specimen of treated and
untreated carbide inserts has been prepared for
microstructure identification. ASTM B 657- 05 standard
procedures for the cemented carbides has been followed
to check any modification in the microstructure due to
revealed the difference
between the microstructure of untreated and treated
black eta phase particles
has been found in treated insert as compared to
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Effect of Direct and Indirect Cryogen Application Methods on the Turning Forces, Tool Wear and Surface Finish of a Nickel Based Alloy
(Nimonic 90)
108-4
Figure 3: microstructure of treated and untreated
insert. (a) Dense eta phase distribution in treated
inserts (b) Sparse eta phase distribution in untreated
insert.
3.4 Cryogenic cooling (Direct cryogenic
application)
In direct cryogen application method, cryogen has
been directly applied to the cutting zone as shown in
Figure 4. Unlike indirect cryogenic approach, untreated
tools have been used during direct cryogenic cooling
method.
Figure 4: schematic of direct cryogenic cooling
3.5 Experimental plan
All experiments have been carried out on Leadwell
T-6 turning centre. Kistler®
piezoelectric multi-
component dynamometer has been used to measure the
cutting forces under different conditions. The surface
roughness has been measured with the help of Taylor
Hobson Surface roughness instrument. Lastly, the tool
wear is measure with the help of Ziess Stereo Discovery
V.20 microscope. Further details of experiments are
provided in table 3.
Table 3: Machining conditions
Cutting Environment Dry, Dry (Cryo treated
tools), Cryogenic
Cutting Speed (m/min) 40,60,80
Depth of cut (mm) 1
Feed rate (mm/rev) 0.1
Nimonic bar
dimensions (mm) Diameter= 60, Length= 300
4 Results and Discussions
All experiments have been conducted under dry,
cryo treated and cryogenic conditions. Cutting forces,
tool wear and surface roughness have been measured for
all these conditions at different speeds after 60 seconds
of machining. Comparison of all these output
parameters has been presented in this paper. Figure 5
shows the comparison of main cutting force (Fz) for all
3 conditions. At all 3 cutting speed values, dry condition
yielded the highest values of cutting force as compared
to cryo-treated and cryogenic conditions. At both 40
m/min and 80 m/min cutting speeds, the reduction of
approximately 4.5% was observed in cutting force
magnitude with cryo treated condition as compared to
dry condition. Whereas for the same speed levels the
cutting force magnitude was found to be reduced by
10% with cryogenic cooling condition as compared to
dry environment. The reduction in cutting force under
cryo-treated condition was mainly due to the formation
of hard eta phase particles during cryogenic treatment of
the tool which has resulted in an improvement in the
wear resistance capability of the tool. While the
formation of lubrication film during cryogenic cooling
condition could be considered as the possible reason for
cutting force reduction under cryogenic machining. The
reduction in the amount of temperature sensitive tool
wear such as: adhesion wear and diffusion wear during
cryogenic cooling could also be a reason for reduction
in cutting force values during direct cryogenic cooling.
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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12
Guwahati, Assam, India
Figure 5: Comparison of cutting force v/s cutting
speed under different cutting conditions
The surface roughness was also measur
cases as shown in Figure 6. Surface roughness in case of
cryo-treated tools was found to be almost equal
different cutting speed conditions. Cryogenic cooling
resulted into inferior surface roughness
cryo-treated conditions. At 40 m/min, cryo
outperformed both dry and direct cryogenic condition in
terms of surface finish value. At this condition surface
roughness of 0.66 μm was obtained with indirect
cryogenic method. Whilst surface roughness of 0.86
and 0.99 μm was produced by dry and direct cryogenic
condition respectively. It has also been observed that
with higher cutting speeds of 60 m/min and 80
dry condition provided better surface roughness as
compared to both cryogenic application methods.
Absence of built up edge formation and material
softening due to higher temperature at higher cutting
speed could be considered as the reason for
improvement in surface finish. At all
cryo treatment method outperformed direct cryogen
method in terms of surface finish. As compared to
cryogenic cooling, the surface roughness was improved
by 33%, 37% and 25% with cryo-treated tools at 40
m/min, 60 m/min and 80 m/min respectively. It could be
concluded that workpiece became brittle
with the direct application of liquid nitrogen
cryogenic cooling method which resulted into poor
surface roughness as compared to dry and cryo
conditions.
Figure 6: Comparison of surface roughness
cutting speed under different cutting conditions
350
400
450
500
40 60 80
Fz(
N)
Cutting speed(m/min)
0
0.5
1
1.5
40 60 80
surf
ace
rou
gh
ne
ss( μμ μμ
m)
m)
m)
m)
Cutting speed(m/min)
All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12
Figure 5: Comparison of cutting force v/s cutting
speed under different cutting conditions
The surface roughness was also measured for all 3
Surface roughness in case of
ools was found to be almost equal the 3
ryogenic cooling
inferior surface roughness than dry and
, cryo-treated tool
outperformed both dry and direct cryogenic condition in
terms of surface finish value. At this condition surface
was obtained with indirect
surface roughness of 0.86 μm
dry and direct cryogenic
It has also been observed that
with higher cutting speeds of 60 m/min and 80 m/min,
better surface roughness as
both cryogenic application methods.
up edge formation and material
softening due to higher temperature at higher cutting
speed could be considered as the reason for
inish. At all cutting speeds,
method outperformed direct cryogen
ace finish. As compared to
cryogenic cooling, the surface roughness was improved
treated tools at 40
m/min, 60 m/min and 80 m/min respectively. It could be
concluded that workpiece became brittle and hardened
application of liquid nitrogen in direct
which resulted into poor
to dry and cryo-treated
e 6: Comparison of surface roughness v/s
cutting speed under different cutting conditions
Flank wear of cutting insert was measured with the
help of Carl Ziess microscope for each
60 sec of machining. Figure 7 shows the flank wear
images for all the 3 conditions at 40 m/min.
found that tool wear in dry condition was
direct and indirect cryogenic condition
Figure 8. At 40 m/min, the flank wear value
µm, 37.32 µm and 34.26 µm was observed with dry,
cryo-treated and cryogenic condition
cryo treatment and cryogenic cooling
method increased the tool life by 30% and 36%
respectively over dry cutting at lower speed level.
higher cutting speed of 60 m/min and 80 m/min,
cryogenically treated tools performed slightly better
than untreated tools used in dry c
improvement of approximately 8% has been observed
with cryo-treated tools over dry
cutting speeds. The improvement observed in the tool
life of cryo-treated inserts was mainly due to the
changed microstructure. Rise in cuttin
temperature could be the possible reason of early tool
failure under dry cutting condition. As compared to dry
and treated tools, the better tool life has been observed
with direct cryogenically cooled tools.
speed of 80 m/min, direct cooling has shown a tool life
improvement of 90% and 77% as compared to dry and
indirect cryogen methods respectively. Possibly a
drastic reduction in cutting tool temperature
the cryogen has resulted in such improved behaviour.
(a)
(c)
Figure 7: Flank wear at 40 m/min under all 3
conditions (a) Dry cutting condition (b) Indirect
cryogenic condition (cryo-treated tool
cryogenic condition
Cutting speed(m/min)
Dry
Cryo-treated
Cryogenic
Cutting speed(m/min)
Dry
Cryo-treated
Cryogenic
All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th–14th, 2014, IIT
108-5
was measured with the
iess microscope for each condition after
Figure 7 shows the flank wear
at 40 m/min. It has been
dry condition was more than
direct and indirect cryogenic conditions as shown in
the flank wear values of 54.07
m was observed with dry,
treated and cryogenic conditions respectively. Both
cooling application
the tool life by 30% and 36%
respectively over dry cutting at lower speed level. At
higher cutting speed of 60 m/min and 80 m/min,
cryogenically treated tools performed slightly better
ools used in dry cutting. An
8% has been observed
eated tools over dry condition at higher
The improvement observed in the tool
treated inserts was mainly due to the
changed microstructure. Rise in cutting zone
temperature could be the possible reason of early tool
failure under dry cutting condition. As compared to dry
and treated tools, the better tool life has been observed
cooled tools. At a cutting
cooling has shown a tool life
improvement of 90% and 77% as compared to dry and
methods respectively. Possibly a
reduction in cutting tool temperature because of
resulted in such improved behaviour.
(b)
Figure 7: Flank wear at 40 m/min under all 3
conditions (a) Dry cutting condition (b) Indirect
treated tool) (c) Direct
cryogenic condition
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Effect of Direct and Indirect Cryogen Application Methods on the Turning Forces, Tool Wear and Surface Finish of a Nickel Based Alloy
(Nimonic 90)
108-6
Figure 7: Comparison of Flank wear v/s cutting
speed under different cutting conditions
5 Conclusions
Cutting force, surface roughness and tool wear have
been measured under dry, indirect and direct cryogenic
environment for machining of Nimonic 90 bars. The
major conclusions that can be drawn from the
experimental results are as follows:
1. Cryo-treated cutting tool inserts outperformed
untreated inserts under dry cutting condition in terms of
cutting force, surface finish and tool life at the selected
cutting speed levels.
2. Direct cryogenic application has also emerged as a
better cutting environment for the sustainable machining
of Nimonic 90 alloy.
3. From surface finish point of view the cryo-treated
method yielded better results as compared to dry and
direct cryogenic condition.
4. Overall both direct and indirect cryogenic methods
are found to be better than dry cutting approach. These
methods are not only eco–friendly but also save the cost
of machining by increasing tool life. Therefore, using
cryogenic approaches one can bring sustainability to the
metal cutting process.
Acknowledgement
The Authors want to greatly appreciate the help
rendered by Dr. Jagtar Singh (Associate Professor in
Mechanical Engineering Department) of SLIET
Longowal, for providing cryogenic treatment facility.
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0
100
200
40 60 80
Fla
nk
we
ar(
μμ μμm
)m
)m
)m
)
Cutting speed(m/min)
Dry
Cryo-treated
Cryogenic