Project Team

University of Massachusetts
Tiefu Shao
Sundar Krishnamurty

Springfield Technical Community College

Gary Masciadrelli
Megan Piccus
John Lafrancis

PMRAP

Zvi Rozen
Dave Cruise
Thomas Langevin

Why Cryogenic Machining?

Environmentally sound.
Higher production rates
Greater tool life
Hogouts

What is Cryogenic Machining?

Using liquid nitrogen (ln2)as a coolant for tools.

Liquid Nitrogen
Temperature -196 C -321 F
Colorless
Inert, doesnt react with other materials
Non toxic
Readily vaporizes into gas.

Keeping Tools Cool

Hardness at Temperature
Carbide tools at room temperature -1600 -1800 kg/mm^2
Carbide at 500 C 1000 1100 kg/mm^2
Carbide at 900 C - 600 500 kg/mm^2

Tool wear at 70m/min @ feed of .20

mm/rev

Project Icefly
Commercialized cryogenic process.
Collaboration between Air Products and Hardinge
machine tool builder. In 2003.
Developed specifically for turning.
Team experimented with some milling.

Summary
Tool life increases up to 40% in Titanium turning.
Tool life increases up to 130% in Hard turning.
Increase in MRR up to 290% in Hard turning.
Increase in MRR up to 60% in Titanium milling.
Tool life increases up to 260% in Titanium milling.

Discussion

Project
Project deliverables
1, Design robust ln2 system to support milling
processes.
2, Build prototype system.
3, Implement and debug system in STCC.
4, Optimize prototype to yield MRR of 25%.
5, Report out to industry.

Project Phases
Develop base line information.
Optimize process.
Design and Build of prototype ln2 milling process.
Implementation of the prototype.
Cost justification for production unit.

Develop base line information

Research current Titanium milling process.
Obtain equipment and materials for testing.
Replicate project ice fly process.

Optimize process
Identify critical process parameters.
Run experiments.
Analyze the data.
Rerun the experiment to confirm analysis.

Design and build prototype ln2 milling

process.
Design.
Design review.
Build

Implementation
Install prototype system.
Debugg system.
Run off the process.

Cost Justification for Production Unit

Obtain costs.
Determine achievable cost savings.
Develop generic project plan for implementation.
Calculate ROI.
Report out to Industry.

Questions?

References

Growth of tool wear in turing of Ti-6Al-44 alloy under cryogenic cooling.

K.A. Venugopal, S. Paul, A.B. Chattopadhyay ( Nov. 2006)
High speed machining of aero-engine alloys
E.O. Ezugwu ( Oct 2003)

An overview of the machinability of aeroengine alloys.

E.O. Ezugwu, J. Bonney, Y. Yamane (Oct 2002)

Experimental investigation of Cryogenic cooling by liquid nitrogen in orthogonal machining

process.
M. Dhananchezian, M. Pradeep Kumar, A. Rajadurai (May 2009)

Effectiveness of cryogenic machining with modified tool holder.

Mirghani I. Ahmed, Ahmad F. Ismail, Y.A. Abakr, A.K.M Nurul Amin ( Mar 2006)

Cryogenic machining with brittle tools and effects on tool life

Ranajit Ghosh, Zbigniew Zurecki, John H. Frey ( Nov. 2003)
Dry machining of metals with liquid nitrogen.
Zbigniew Zurecki, George Harriot, Xiaoguang ( Oct. 1999)