Flow characteristics of optimized hybrid cryogenic-minimum quantity lubrication cooling in machining of aerospace materials

Abstract Recent trends aim at efficient and sustainable cooling strategies for machining hard-to-cut materials. This research is concerned with combining cryogenic cooling and minimum quantity lubrication to benefit from their respective cooling and lubrication capabilities. Fundamental understanding of the flow characteristics of the two jets, their interaction, and relative position was carried out using experimentally validated CFD and FE modelling of the cutting zone. The performance of the optimized hybrid system was evaluated experimentally and compared to flood, high pressure and cryogenic cooling in machining of Ti-alloys. Results showed an improvement in tool life when using the optimized hybrid cooling technique.