Comparison of Machining Performance of Ti-6Al-4V under Dry and Cryogenic Techniques Based on Tool Wear, Surface Roughness, and Power Consumption

The machining of Ti-6Al-4V alloys is challenging due to their high strength, poor thermal conductivity, and high chemical reactivity. When used in traditional machining, cryogenic coolants can reduce tool wear, thus extending tool life, improving surface finish, and requiring less power with reduced environmental effects. In this context, this study aimed to perform a machinability analysis of the surface roughness, power consumption, tool wear, and specific energy consumption of a Ti-6Al-4V titanium alloy and to comprehend the performance of dry and cryogenic machining in turning operations. A comprehensive analysis of tool wear and specific cutting energy (SCE) under dry and cryogenic machining was conducted. It was found that the machining time under a cryogenic environment was increased by 83% and 39% at 80 and 90 m/min compared to a cutting speed at 100 m/min. The higher cutting speed (100 m/min) in cryogenic environments produced an improved surface finish. Compared to dry machining, the cooling effect of liquid CO2 helped dissipate heat and reduce thermal damage, improving surface finish. The findings revealed that in dry conditions, approximately 5.55%, 26.45%, and 27.61% less power was consumed than in cryogenic conditions at 80, 90, and 100 m/min cutting speeds, respectively. Based on the outcomes of the work, the application of cryogenic cooling can be considered an alternative to dry and flood cooling for improving the machinability of Ti-6Al-4V alloys.