Tool chip contact length analysis of dry and cryogenic turning of aerospace alloy Ti-6Al-4V

Tool chip contact length is a vital machining index being representative of manufacturing efficiency. Various machining factors including tool wear and energy consumption are governed by tool chip contact length. The current work was undertaken to make a comparative analysis of dry and cryogenic turning of Ti-6Al-4V in terms of their sustainability and productivity indices. During experimentation, cutting speeds of 50 m/min and 125 m/min were selected working at feed rates ranging from 0.16 mm/rev to 0.24 mm/rev. Scanning electron microscopy was utilized to analyse the results. It was observed that machining under cryogenic conditions, in comparison with dry conditions, resulted in up to 51 % lower tool chip contact length. The results were also investigated in terms of chip formation for both machining environments. In addition, benefits of lower tool chip contact length were quantified in terms of lesser tool wear and better energy consumption. Tool chip contact length and chip formation analysis, indicative of the machining process efficiency, highlights that cryogenic condition is more sustainable and productive than dry conditions.