A study of temperature effects in modulation-assisted machining

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Natarajan, Arvind
Moscoso-Kingsley, Wilfredo

Machining is a process that involves extreme physical and chemical interactions between cutting tools and work materials. The extreme interactions lead to high tool wear and intensive energy expenditure; and, to mitigate these undesirable effects, polluting lubricants/coolants are often deployed. The high tool wear and energy expenditure, and the use of polluting fluids results is high operational costs and environmental impacts. Thus, it would be desirable to formulate machining methods that significantly reduce the extreme physical and chemical interactions, without having to employ toxic fluids. To define such methods, fundamental research is still needed. Fundamental research potentially leading to the formulation of a highly cost/environmentally friendly machining method is the topic of this thesis. The method to be employed will combine the application of a controlled modulation on the tool path and the injection of a cryogenic fluid (liquid nitrogen (LN2)) to produce a disruption of the chip-tool contact that will, presumably, allow for greater penetration of the cryogenic substance. The efficacy of the method has been evaluated by the temperature at the chip-tool interface. In spite of the significant role of the chip-tool interface temperature in the tool wear process, the temperature arising from the use of modulation and coolants is not well defined in the literature. The setup to be utilized has been designed and tested for functionality. The setup has also been used to observe the temperature at the chip-tool interface during modulation and conventional cuts, under the action of air and LN2. The machining force was also evaluated during conventional cuts. The correlation between temperature and force, where available, is summarized.

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Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Industrial and Manufacturing Engineering