Enhancing Machining Efficiency of Ti-۶Al-۴V: The Role of Coolants and Advanced Cooling Technologies

The main titanium alloys, especially Ti-۶Al-۴V, are highly appreciated for their strength-to-weight ratio and corrosion resistance; consequently, they are considered crucial in industries such as aerospace, medical, and automotive technology. Machining of Ti-۶Al-۴V is very difficult due to its low thermal conductivity (around ۷ W/m·K), high tensile strength (۹۰۰ MPa), and tendency to work harden at high cutting speeds and feeds. In such regards, effective cooling strategies must be applied in order to decrease heat at the cutting interface, increasing tool life and enhancing surface quality. Traditional flood cooling techniques can decrease cutting temperatures by ۲۰-۳۰% and increase tool life up to ۵۰%; however, they also generate significant coolant waste and raise environmental concerns. Minimum Quantity Lubrication (MQL) reduces coolant usage up to ۹۰% while simultaneously giving similar improvements in tool life (ca ۳۰%) and resulting in a reduced environmental impact. New lubricants, such as nanofluids, improve thermal conductivity by up to ۴۰%, which helps reducing cutting temperatures and increasing tool life by ۲۰%. Cryogenic cooling, either with liquid nitrogen or carbon dioxide, can potentially reduce cutting temperatures about ۶۰%, increasing tool life and improving surface quality significantly; however, high costs and complexity inhibit more widespread use. This study takes a quantitative approach to the assessment of coolant methods, considering trade-offs among cooling effectiveness, environmental impact, and operating cost. Further research in the development of novel cooling technologies is essential in the quest for optimal machining of Ti-۶Al-۴V for improved performance and sustainability.

کلیدواژه ها:

Machining of Ti-۶Al-۴V ، Coolant ، Cooling Methods