STUDY OF CRYOGENIC MACHINING FOR SINGLE TIP CUTTING TOOL

USING NEW COOLING SYSTEM DESIGN

HAZWAN AIZAT BIN MOHAMED HUSSIN

A report submitted in partial fulfillment of the requirements

For the award of the degree of
Bachelor of Mechanical Engineering with Manufacturing

Faculty of Mechanical Engineering

UNIVERSITI MALAYSIA PAHANG

NOVEMBER 2008
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SUPERVISOR’S DECLARATION

We hereby declare that we have checked this project and in our opinion this project is
satisfactory in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering with Manufacturing.

Signature : ………………………….
Name of Supervisor : En. Zamzuri Bin Hamedon
Date : November 2008

Signature : …………………………….
Name of Panel :
Date : November 2008
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STUDENT’S DECLARATION

I declare that this final year project report entitled “Study of Cryogenic Machining for
Single Tip Cutting Tool Using New Cooling System Design” is the result of my own
research except as cited in the references. The report has not been accepted for any
degree and is not concurrently submitted in candidature of any other degree.

Signature : ………………………………
Name of Candidate : Hazwan Aizat Bin Mohamed Hussin
Date : November 2008
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Dedicated to my dearest parent.

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ACKNOWLEDGEMENT

First of all, thanks you the Almighty god, Allah S.W.T for blessing me finish this
project successfully. Special gratitude express to my supervisor En. Zamzuri Bin
Hamedon for his brilliant idea, invaluable guidance, continuously encouragement and
constant support in making this project possible. His knowledge, experiences and
technical skills always impress me and open my minds to always think differently than
what written in text books or lectures to solve any technical problems.
Besides that, my sincere thanks to my lab mates who teach me a lot to handle
machines that I was going to use. Not forget also to Mechanical Lab staffs that done
really good jobs monitoring and assisting in technical support during the fabrications.
I would like to thanks also to my beloved parent for their dreams and faith in me.
Their pray will always follow and help me whenever I goes. Lastly, to all university staff
from Mechanical Engineering Faculty, my fellow friends and who was helping
indirectly, thanks for giving me such a sincere support and assistance.
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ABSTRACT

This project deals with a cryogenic cooling approach for a lathe machine. In steel
machining, high cutting temperature will result reduce in cutting tool life and also
reduce the product machined quality. Nowadays, conventional cutting fluid used to
control the high cutting temperature but it still ineffective. Soluble oil is the favorable
conventional cutting fluid used. Unfortunately, it leads to environment pollution
problem especially when its dispose to the earth. Cryogenic cooling which is an
environmental friendly cutting fluid or called as coolant can help rids of conventional
cutting fluid pollution problem and ineffective controlling cutting temperature. Present
works are design and fabricate cryogenic coolant system that suit with a conventional
lathe machine. Three cylindrical AISI 1045 steel tested with TNMG TT5100 which is a
Chemical Vapor Deposition (CVD) coated cutting tool insert. The result compared with
dry machining, machining with soluble oil as coolant and cryogenic machining which
use nitrogen gas as the coolant. Results indicate the benefit of cryogenic cooling in
cutting tool life and workpiece surface finish. This may attributed by the reduction of
cutting zone temperature. Further more, from the result proves that soluble oil failed to
improve cutting tool life and product surface finish.
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ABSTRAK

Projek ini melibatkan cara penyejukan secara kriogen untuk sebuah mesin larik. Dalam
memesin besi, suhu pemotongan yang tinggi akan menyebabkan pengurangan jangka
hayat bagi alat pemotong dan mengurangkan kualiti produk yang dimesin. Kini, cecair
pemotong biasa digunakan untuk mengawal suhu pemotongan yang tinggi tetapi ia
masih tidak efektif. Minyak terlarut ialah cecair pemotong biasa yang paling digemari
digunakan. Akan tetapi, ia menyebabkan masalah pencemaran alam terutama sekali
apabila dibuang ke bumi. Penyejukan secara kriogen iaitu sejenis cecair pemotong yang
mesra alam atau dipanggil sebagai cecair penyejuk boleh membantu menyelesaikan
masalah pencemaran cecair pemotong biasa dan kawalan suhu memotong yang tidak
efektif. Tugasan ini ialah mereka bentuk dan membina sistem cecair penyejuk kriogen
yang sesuai dengan mesin larik biasa. Tiga silinder AISI 1045 besi dicuba dengan
TNMG TT5100 iaitu mata pemotong jenis selaputan Pemendapan Wap Kimia (CVD).
Keputusan dibandingkan antara memesin secara kering, memesin dengan minyak
terlarut sebagai cecair penyejuk dan memesin secara kriogen yang menggunakan gas
nitrogen sebagai cecair penyejuknya. Keputusan menunjukkan kelebihan penyejukan
kriogen dalam jangka hayat alat pemotong dan permukaan benda kerja. Ini mungkin
disebabkan oleh pengurangan suhu zon pemotongan. Tambahan pula, daripada
keputusan membuktikan bahawa minyak terlarut gagal untuk memperbaiki jangka hayat
alat pemotong dan permukaan produk.
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TABLE OF CONTENTS

Page
SUPERVISOR’S DECLARATION ii
STUDENT’S DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF SYMBOLS xiii
LIST OF ABBREVIATIONS xiv

CHAPTER 1 INTRODUCTION

1.1 Introduction 1
1.2 Project Background 1
1.3 Problem Statement 2
1.4 Project Objectives 2
1.5 Project Scopes 3

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 4
2.2 Lathe Machine
2.2.1 Introduction 4
2.2.2 Machine Components and Features 5
2.2.3 Cutting Tool Types and Operations 8
2.2.4 Cutting Parameters 9
2.2.5 Safety Consideration for Lathe Machine 13
2.3 Coolant/Cutting Fluid
2.3.1 Introduction 14
2.3.2 Coolant Purposes 14
2.3.3 Coolant Applied Method 15
2.3.4 Cryogenic Coolant 16
2.3.5 Safety Considerations for Cryogenic Coolant 18
2.4 Nozzle
2.4.1 Introduction 19
Comparison of Using Nozzle and Tool Holder to Transmit
2.4.2 20
Coolant
2.5 Conclusion 21
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CHAPTER 3 METHODOLOGY

3.1 Introduction 22
3.2 Overview of the Methodology 22
3.3 Designing
3.3.1 Nozzle 24
3.3.2 Nozzle Holder 26
3.3.3 Hose Arrangement 27
3.4 Fabrication
3.4.1 Fabrication of Nozzle 28
3.4.2 Fabrication of Nozzle Holder Long Rod Part 30
3.4.3 Fabrication of Nozzle Holder Clamping Part 32
3.4.4 Fabrication of Nozzle Holder Hose Holder Part 34
3.5 Testing
3.5.1 Testing Parameters 37
3.5.2 Workpiece Preparation 38
3.6 Analysis
3.6.1 Analysis of Surface Roughness 42
3.6.2 Analysis of Cutting Tool Wear 43
3.7 Conclusion 43

CHAPTER 4 RESULTS AND DISCUSSIONS

4.1 Results
4.1.1 Tool Wear 44
4.1.2 Surface Roughness 46
4.2 Discussions
4.2.1 Tool Wear 49
4.2.2 Surface Roughness 50

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 51
5.2 Recommendation 53

REFERENCES 54
APPENDICES
A Project flow chart 55
B Project Gantt chart 58
C Lathe machining environments/cooling apply method 61
D Detail drawing 63
E Exploded View 68
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LIST OF TABLES

Table No. Page

1 Characteristic temperatures of cryogenic fluid. 17

2 Properties of helium and nitrogen. 18

3 Testing parameters. 38

4 Workpiece surface roughness for three different machined environments. 48

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LIST OF FIGURES

Figure No. Page

1 Lathe machine. 5

2 Headstock. 5

3 Carriage. 6

4 Tailstock. 7

5 Standard cutting tool. 8

6 Insert cutting tool. 8

7 Typical straight turning. 10

8 Workpiece depth of cut (DOC) determines. 12

9 Workpiece surface roughness determines. 13

10 Temperature distribution at the cutting zone. 15

11 Coolant transmitted by nozzle. 21

12 Coolant transmitted by modified tool holder. 21

13 Cryogenic cooling system setup. 23

14 Nozzle direction. 25

15 Nozzle side view. 25

16 Nozzle holder design. 26

17 Lathe machine carriage track. 26

18 Nozzle old design. 36

19 Nozzle new design 37

20 Workpiece dimension. 38

21 Cutting tool movement. 39

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22 Testing with dry machining environment. 40

23 Testing with wet machining environment. 41

24 Testing with cryogenic machining environment. 41

25 Perthometer. 42

26 IM7000 Series Image Analyzer. 43

27 Tool insert crater wear for dry machining. 45

28 Tool insert crater wear for wet machining. 45

29 Tool insert crater wear for cryogenic machining. 46

30 Printed surface roughness graph from perthometer for dry machining. 47

31 Printed surface roughness graph from perthometer for wet machining. 47

32 Printed surface roughness graph from perthometer for cryogenic machining. 48

33 Comparison of average surface roughness. 49

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LIST OF SYMBOLS

N Spindle speed

Cs Cutting speed

D Workpiece diameter

π Pi (3.142)

µ Micro (×10-6)

Ra Average surface roughness

× Multiply

in Inch

LN2 Liquid nitrogen

N2 Nitrogen gas

mm Millimeter

rev Revolution

Ø Diameter

Lt Travel length

m Meter
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LIST OF ABBREVIATIONS

IPM Inch per minute

IPR Inches per revolution

DOC Depth of cut

RMS Root mean square

EDM Electro discharge machine

AISI American Iron and Steel Institute

rpm Revolution per minute

CVD Chemical vapor deposition

DRO Digital read out

 CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

Cryogenic becomes one of the most suitable coolants (cutting fluid) to replace
the flood type coolants that already available at almost conventional lathe machine
nowadays. Most of CNC lathe machine equipped with soluble oil which is a type of
flood coolant. From the research that already done by researcher such as Mirghani I.
Ahmed, Yakup Yildiz, etc., cryogenic will enhance lathe machine cutting tool life better
than what a flood coolant can do. Cost and set up time can be reduce because cutting
tool is the critical part of lathe machine that always breaks. The objectives of this project
is to equip a conventional lathe machine with a cryogenic coolant system by fabricate it
from the cryogenic dewar/cylinder to the nozzle. Three different machining
environments will be done to compare the chips produced as the evidence of goodness
of cryogenic coolant.

1.2 PROJECT BACKGROUND

Lathe machine is the most common machine in a manufacturing plant. Usually, a

small plant used conventional lathe machines in their metal cutting process. The
conventional machine needs good skills operator to handle it so that the metal that been
cut will result fine finish surface. Even a good skills operator handle it, machine
breakdown still might be happen. The critical part that usually breaks at the machine is
the cutting tool. Higher feed rate and excessive forces applied are some of the causes
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that contribute cutting tool to break. A flood type coolant system already installed with a
conventional machine when brought from its factory. The coolant gives a little help to
decrease the percentage for the cutting tool to break. So, a type of mist coolant system
would necessary considered as the replacement for the flood type coolant system
because of its ability to enhance cutting tool life better.

1.3 PROBLEM STATEMENTS

The general purpose for any project is to find solutions on a certain problems.
It’s also gives main idea how the project to be completed. For this project, the problems
that need to be solved are:-
1) Any manufacturer wants to reduce cost and time taken to complete a product but
gives better quality products and increases the outputs.
2) Manufacturer tends to upgrade their machines to compete with the new machine
with new technology.
3) Lathe machine cutting tool can easily break and needs to enhance its tool life.

1.4 PROJECT OBJECTIVES

Every works must come out with its own objectives so that its will achieves the
goal successfully. For this project, the objectives are:-
1) To design a cooling system for a lathe machine.
2) To fabricate the cooling system that use cryogenic as the coolant.
3) To test the lathe machine operates with its newly installed coolant system.
4) To analyze the cutting tool wear and workpiece surface roughness.
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1.5 PROJECT SCOPES

The general scopes for this project are:-

1) Do the literature reviews on lathe machine, coolant or cutting fluid and nozzle.
2) Choose the cryogenic coolant type for the project study. Interest in nitrogen gas
(N2) for the cryogenic coolant.
3) Develop Gantt chart and flow chart for this project.
4) Design the coolant nozzle by using SolidWork software.
5) Nozzle holder designed by using SolidWork software.
6) Coolant hose arrangement designed to the coolant system.
7) Fabricate designed coolant nozzle by using lathe machine and drilling machine.
8) Fabricate nozzle holder by using milling machine.
9) Test the coolant system with three different machining environments.
 CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

Coolant or cutting fluid widely used in metal machining operations such as for
drilling machine, lathe machine and milling machine. The purposes of coolant are to
wash away chips from the tool, reduce heat generated, reduces frictions between tool
and workpiece and also to enhance tools life. Most of the CNC machines are already
installed with a coolant system by the manufactured factory itself. For this project, a
lathe will be installed with a coolant system that use cryogenic as the coolant which is a
mist coolant type. The common lathe machine used fluid as its coolant. A nozzle used to
transmit cryogenic from its tank to the tool or workpiece at the lathe machine.

2.2 LATHE MACHINE

2.2.1 Introduction

Lathe machine (Figure 1) is a metal removal machine that used for shaping
metals and sometimes wood or other materials by held the workpiece and rotated its
while the cutting tool advanced to the workpiece and causing the cutting action. The
basic lathe machine was designed to cut cylindrical workpiece shape, but now its has
been developed further and can produce screw, threads, tapered work, drilled holes,
knurled surfaces and crankshafts. The typical lathe machine provides with variety of
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rotating speeds and can manually or automatically move the cutting tool towards the
workpiece.

Figure 1: Lathe machine (Wikipedia.com)

2.2.2 Machine Components and Features

Lathe machine consists of four basic or main parts which are headstock
(Figure 2), carriage (Figure 3) and tailstock (Figure 4). Every main part also consists of
other parts which is very important to every machinist to know before using the
machine. Other components that are not stated before are bed, cooling pump and brake.
Bed connects the headstock with carriage and tailstock. Bed also acts as a rail for
carriage and tailstock to travel. Cooling pump supplies cooling fluids via a hose towards
a desires direction. Brake which is located below the bed used when there is an
emergency happen and needs to stop the spindle immediately.

Headstock

Figure 2: Headstock (Wikipedia.com)

(H1) Gear headstock housing – House the spindle, speed change mechanism and change
gears.
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(H2) Intermediate gear lever – Controls the rotational speed.

(H3) High low gear level – Controls the rotational speed.
(H4) Spindle – Holds and drives workpiece.
(H5) Tumbler gears – Enables a gear train of the correct ratio and direction.
(H6) Quick change gear box with 4 selectors (3 levers) – Change gears.
(H7) Lead screw – Transmits power from the headstock to the carriage for screw thread
cutting operations.
(H8) Feed screw – Transmits power from the headstock to the carriage for feeding
operations.
(H9) Forward-reverse switch – Control the forward and reverse carriage mechanism.
(H10) Change gear cover – House the change gears.

Carriage

Figure 3: Carriage (Wikipedia.com)

(1) Toolpost – Mounted the tool bit.

(2) Top-slide – Mounted toolpost and provide small movement along Z-axis.
(2a) Top-slide feedscrew and dial – Move the top-slide to assist in making reproducible
cuts.
(2b) Protractor – Guide top-slide if an angle needed for cutting.
(3) Cross-slide – Used for manual positioning along X-axis.
(3a) Cross-slide Digital Read Out (DRO) scale – Gives operator the exact coordinates of
the tool with respect to workpiece.
(3b) Cross-slide feedscrew and dial – Move the cross-slide to assist in making
reproducible cuts.
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(4) Saddle – Mounted cross-slide.

(5) Apron – Lube oil reservoir that lubricates the apron gears.
(5a) Carriage handwheel – Move the carriage along the bed.
(5b) Half-nut lever – Engages the carriage directly to the lead screw and used only for
threading. Only engage when the feed is set in the neutral position.
(5c) Feed lever – Controls the automatic movement of the Z and X axes.

Tailstock

Figure 4: Tailstock (Wikipedia.com)

(T1) Feed screw – Move the spindle longitudinally.

(T2) Reduction gear box (optional) – Only found in larger center lathes where large
drills may necessitate the extra leverage.
(T3) Body – Contain the extent of spindle and as the housing for other tailstock
components.
(T4) Adjustable base – Provision to offset the tailstock.
(T5) Spindle – Does not rotate. Include a taper to hold drill bits, centers and other
tooling.
(T6) Locking lever – Clamps the tailstock at a fix position.
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2.2.3 Cutting Tool Types and Operations

There are two types of cutting tool which are the standard cutting tool (Figure 5)
type and insert cutting tool (Figure 6) type which is the insert comes out with different
shapes depends on the operation. The cutting tool will be hold by tool holder located at
toolpost at carriage. For lathe machine, the tool is moving with the direction set up by
the carriage towards the rotating workpiece. Cutting fluid or coolant needed in cutting
operation, so that it will enhance tool life and gives better workpiece surface finish. Tool
can easily break if there is no coolant exists especially when high feed rate applied.

Figure 5: Standard cutting tool [1]

Figure 6: Insert cutting tool [2]

There are also lot of operations can be held at the lathe machine. Each operation
used different type of tools. Turning, facing, parting, drilling, boring and thread turning
are the operations that can be held by lathe machine.
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Turning
Turning operations is for reducing the workpiece diameter to a desired dimension.
Roughing tool used for roughly cut the workpiece into a diameter and then, finishing
tool will improve the workpiece surface.

Facing
Lathe machine used a facing tool when want to create a smooth flat face very accurately
perpendicular to cylindrical workpiece axis. If a finer finish is required, repeat the facing
operation final cut used the power feed.

Drilling
Lathe machine can drill a hole accurately concentric with centerline of cylindrical
workpiece. A drill chuck is installed at the tailstock by withdraw the jaws of chuck and
tap drill chuck in place with soft hammer.

Boring
Boring is an operation to enlarge a hole with a single point cutting. A boring bar is used
to support the cutting tool as it extends into the hole. Lower spindle speed required
during this operation because the tool is supported less rigidly.

Thread Turning
A special cutting tool used typically with a 60 degree nose angle. To form threads with a
specified number of threads per inch, the spindle is mechanically coupled to the carriage
lead screw.

2.2.4 Cutting Parameters

When metal is cut, the workpiece surface is driven with respect to the tool, or the
tool with respect to surface, at a relatively high rate of speed. This is called cutting speed
(Cs). Mostly the tool or workpiece revolves. Almost all such machine tools are calibrated
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in revolutions per minute (rpm). The cutting speed is related to the rpm and thus is
conveniently expressed in meter per minute (m/min).
Spindle speed (rpm) is the rotational frequency of lathe machine spindle and its
determined based on the type of material to be cut. Soft steel such as aluminium alloy is
suitable with high spindle speed during machining. If hard steel such as bronze applied
excessive spindle speed, it will cause premature tool wear, breakage, and can cause tool
chatter. Using the correct spindle speed for the material and tools will affect tool life and
the quality of the surface finish. For a straight turning operation, the spindle speed is
determined from the relationship of

(Eq. 1)

where
N = Spindle speed (rpm)
Cs = Cutting speed (m/min)
D = Workpiece diameter (mm)

Figure 7: Typical straight turning (CustomPartNet.com).