Investigation of high-speed cryogenic machining based on finite element approach

The simulation of cryogenic machining process because of using a three-dimensional model and high process duration time in the finite element method, have been studied rarely. In this study, to overcome this limitation, a 2.5D finite element model using the commercial finite element software ABAQUS has been developed for the cryogenic machining process and by considering more realistic assumptions, the chip formation procedure investigated. In the proposed method, the liquid nitrogen has been used as a coolant. At the modeling of friction during the interaction of tools – chip, the Coulomb law has been used. In order to simulate the behavior of plasticity and failure criterion, Johnson-Cook model was used, and unlike previous investigations, thermal and mechanical properties of materials as a function of temperature were applied to the software. After examining accuracy of the model with present experimental data, the effect of parameters such as rake angle and the cutting speed as well as dry machining of aluminum alloy by the use of coupled dynamic temperature solution has been studied. Results indicated that at the cutting velocity of 10 m/s, cryogenic cooling has caused into decreasing 60 percent of tools temperature in comparison with the dry cooling. Furthermore, a chip which has been made by cryogenic machining were connected and without fracture in contrast to dry machining. © 2017, Brazilian Association of Computational Mechanics. All rights reserved.