RESEARCH PAPER

International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009

Experimental Investigation of Cryogenic Cooling by

Liquid Nitrogen in the Orthogonal Machining Process
M.Dhananchezian1,*, M. Pradeep kumar 1, A. Rajadurai 2
1

Department of Mechanical Engineering, Anna University Chennai, India.

* Email: dhanachezian@yahoo.co.in
Email: pradeep@annauniv.edu
2
Department of Production Technology, Anna University Chennai, India.
Email: rajadurai@annauniv.edu
____________________________________________________________________________________________________________________
Abstract
Cutting temperature is the determining factor for other machinability indices of material. The conventional cutting fluids are
ineffective in controlling the cutting temperature in the cutting zone. Cryogenic cooling is environmental friendly new approach for
desirable control of cutting temperature. Current work involved the experimental study of the effect of cryogenic cooling on cutting
temperature, cutting force, chip thickness and shear angle in the orthogonal machining of AISI 1045 steel and Aluminium 6061-T6
alloy. It has been observed that in cryogenic cooling method, the temperature was reduced to 1928% and the cutting force was
increased to a maximum of 15% then dry machining of AISI 1045 steel. In machining of Aluminium 6061-T6 alloy, the temperature was
reduced to 2739% and the cutting force was increased to a maximum of 10%.
Keywords: Orthogonal machining, Cryogenic cooling, Cutting temperature, Cutting force.

_______________________________________________________________________________________
cryogenic machining of Ti-6Al-4V. Temperatures in cryogenic
machining were compared with conventional dry cutting and
emulsion cooling. It was showed that a small amount of liquid
nitrogen applied locally to the cutting edge is superior to
emulsion cutting in lowering the cutting temperature. Hong et
al [3] have carried out experimental investigation into the role
of cryogenic cooling by liquid nitrogen on friction and cutting
force in machining of Ti-6Al-4V. The experimental results
indicated that cutting force was increased in cryogenic
machining. It was also found that the friction coefficient on the
tool-chip interface was considerably reduced in cryogenic
machining. Dhar et al [4] involved experimental investigation
of cryogenic cooling on tool wear, surface roughness and
dimensional deviation in turning of AISI 4140 steel by two
different geometries of carbide inserts. Substantial benefit of
cryogenic cooling on tool wear, surface roughness and
dimensional deviation was reported. Dhar and Kamruzzaman
[5] conducted an experiment on cryogenic cooling and stated
that benefits of cryogenic cooling are mainly by substantially
reducing the cutting temperature, which improves the chip-tool
interaction and maintains sharpness of the cutting edge and
also shows better surface finish and higher dimensional
accuracy as compared to dry and wet machining.
Paul et al [6] investigated the tool wear and tool life
of carbide inserts in turning of Ti-6Al-4V alloy under dry, wet
and cryogenic environment. It was found that tool wear

I. INTRODUCTION
The most emerging needs of the modern metal cutting
operation are to increase the material removal rate with better
surface finish and high machining accuracy. These objectives
can be achieved by reducing cutting temperature in the cutting
zone. In metal cutting process, high cutting temperature and its
detrimental effects are generally reduced by proper selection
of process parameters, proper selection application of cutting
fluid and using heat and wear resistance cutting tool materials.
The conventional coolants are fails to provide desirable control
of cutting temperature in the cutting zone and also it creates
some techno-environmental problems such as disposal and
dermatological problems to the user. These problems were
eradicated using liquid nitrogen as coolant in cryogenic
machining due its excellent cooling ability along with
environmental friendliness.
II. LITERATURE REVIEW
Wang et al [1] have carried out turning of ceramics
[Si3N4] with Polycrystalline Cubic Boron Nitride [PCBN]
under cryogenic cutting conditions and reported that liquid
nitrogen cooling system reduced the cutting tool temperature
and tool wear over dry machining. Hong and Ding [2]
conducted an experiment with various cooling approaches in

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RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009
parameters are less in cryogenic environment. Ahmed et al [7]
conducted the experiment in cryogenic machining of AISI
4340 steel with modified tool holder. Two different flow
outlets were tested for this modified tool holder. It was found
that this modified tool holder for cryogenic cooling is more
effective when the coolant out flow is directed away from the
cutting edge of the carbide insert. Kalyan kumar and
Choudhury [8] studied the effect of cryogenic cooling on tool
wear and high frequency dynamic cutting forces generated
during high speed machining of stainless steel. It was showed
that cryogenic cooling was effective in bring down the cutting
temperatures that attributed for the substantial reduction of the
flank wear.
However, more work is needed to explore the
potentiality of cryogenic cooling. So the major objective of the
present work is to study the effect of cryogenic cooling on
cutting temperature, cutting force, chip thickness and shear
angle in the orthogonal machining of AISI 1045 steel and

Aluminium 6061-T6 alloy. The effectiveness of cryogenic

cooling was compared with that of dry machining.
III. EXPERIMENTAL CONDITIONS AND PROCEDURE
The orthogonal cutting experiments were carried out on
AISI 1045 steel and Aluminium 6061-T6 alloy tubes with the
outer diameter of 80mm and the wall thickness of 2mm under
dry and cryogenic cutting conditions. The experimental details
are given in Table 1. The cryogenic cooling setup is shown in
Fig.1. In cryogenic cutting conditions, liquid nitrogen was
supplied at the rake face of the cutting tool using a specially
designed nozzle. The photographic view of the experimental
set up is shown in Fig.2. The temperature was measured using
non-contact type Infrared pyrometer with an accuracy of
1.0C in all machining conditions. On line measurement of
the cutting force was carried out using a kistler type 9257B
Piezo-electric three component dynamometer, a Kistler type
5070A12100 multi channel charge amplifier and a PC based
data acquisition system (Dynoware).

Table 1.
Experimental conditions.
__________________________________________________________________________________________________________________________________
Parameter
Group I
Group II
__________________________________________________________________________________________________________________________________
Work material

AISI 1045 steel

Aluminium 6061-T6 alloy

Diameter (mm)

80

80

Wall thickness (mm)

Length (mm)

250

250

Cutting tool

Multi coated carbide

Un coated carbide

Cutting velocity (m/min)

54 and 193

54 and 193

Feed rate (mm/rev)

0.079, 0.119 and 0.159

0.079, 0.119 and 0.159

Environment

Dry and Cryogenic (Rake cooling)

Dry and Cryogenic (Rake cooling)

Compressor

Drier

Pressure
Regulator

Presure
relief valve

Insulated stainless
steel hose
Nozzle

Pneumatic
hose

Stainless
steel pipe

Fig.1. Schematic diagram of cryogenic cooling setup.

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Stainless
steel cap

Stainless
steel pipe

RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009
The comparison of cutting force for AISI 1045
steel and Aluminium 6061-T6 alloy with feed rates for
different cutting velocities under dry and cryogenic
machining were shown in Figure 3 and 4 respectively. It
clearly appears that cutting force increases with the
increase in feed rate due to increase in chip load and also
cutting force decreases with the increase in cutting speed
due to decrease in shearing area. The result indicates that
increased cutting force in cryogenic machining over dry
machining in all cutting conditions. The purpose of using
liquid nitrogen as cooling medium is to lower the cutting
temperature in the cutting zone. The workpiece material
becomes harder and less sticky at lower temperature and
thus resulting in an increased cutting force and reduction
in adhesion between chip-tool interface. The influence of
cryogenic cooling increases the cutting force to a
maximum of 15% and 10% for the machining of AISI
1045 steel and Aluminium 6061-T6 alloy respectively.

Fig. 2. Photograph view of the experimental set-up.

IV. EXPERIMENTAL RESULTS AND DISSCUSSIONS

The present experimental study involves
orthogonal machining of AISI 1045 steel and Aluminium
6061-T6 alloy tubes were carried out under dry and
cryogenic environment. The experimental results of
cryogenic cutting temperature, cutting force, chip
thickness and shear angle have been compared with dry
machining.

1200

1000

Cu t t ing f or ce ( N )

800

A. Effect of Cryogenic Cooling on Cutting Temperature

Table 2 shows that percentage reduction in
cutting temperature due to cryogenic cooling. It is
observed that cryogenic cooling using liquid nitrogen
reduces cutting temperature by 19-40% depending upon
the levels of the cutting parameters (cutting velocity and
feed rate). This is because liquid nitrogen was applied in
the tool rake face. The result indicates that cryogenic
cooling effect slightly decreases with the increase in
cutting velocity and feed rate. The cryogenic cooling
effect mainly depends on cutting speed and feed rate.
Based on the results, the cryogenic cooling effect
decreased because of increase the cutting temperature
there by changing the chip-tool contact nature.

600

400

Cu t t ing velocit y - 5 4 m / m in ( D r y)
Cut t ing velocit y - 5 4 m / m in ( Cr yoge nic)
Cut t in g velocit y - 1 9 3 m / m in ( D r y)

200

Cut t in g velocit y - 1 9 3 m / m in ( Cr yoge nic)

0
0

0 .0 5

0 .1

0 .1 5

0 .2

Fe ed r a t e ( m m / r ev)

Fig.3. Comparison of cutting force under dry and cryogenic machining

of AISI 1045 steel.
400

350

Cu t t in g f or ce ( N )

300

Table 2.
Reduction in cutting temperature due to cryogenic machining.

250

200

150
Cu t t in g velocit y - 5 4 m / m in ( D r y)

S.No

Cutting
Velocity
(m/min)

Feed rate
(mm/rev)

1
2
3
4
5

54
54
54
193
193

0.079
0.119
0.159
0.079
0.119

193

0.159

100

Reduction in cutting
temperature (%)
Aluminium
AISI 1045
6061-T6
steel
alloy
27.61
39.05
26.17
37.30
25.20
35.12
22.67
32.64
21.20
30.26
19.57

Cu t t in g velocit y - 5 4 m / m in ( Cr yoge n ic)

Cu t t in g velocit y - 1 9 3 m / m in ( D r y)
50
Cu t t in g velocit y - 1 9 3 m / m in ( Cr yoge n ic)
0
0

0 .1

0 .1 5

0 .2

Fe e d r a t e ( m m / r ev)

Fig.4. Comparison of cutting force under dry and cryogenic machining

of Aluminium 6061-T6 alloy.

C. Comparison of Chip Thickness

27.98

Figure 5 and 6 shows the chip thickness for dry

and cryogenic machining of AISI 1045 steel and
Aluminium 6061-T6 alloy respectively. It clearly reveals
that increase in chip thickness with the increase in the

B. Comparison of Cutting Force

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0 .0 5

RESEARCH PAPER
International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009

feed rate and also the decrease in chip thickness with the
increase in cutting speed. The reduction in chip thickness
was observed to be maximum of 15% and 25% in
cryogenic machining of AISI 1045 steel and Aluminium
6060-T6 alloy respectively. This is because of better
lubrication effect produced by the liquid nitrogen at the
chip-tool interface due to the formation of fluid cushion.
Reduced the chip thickness in cryogenic machining
results from the lowered cutting temperature and reduced
adhesion between the tool and chip.

Dr y cut t ing

Sh e a r a n gle ( de gr e e )

20

15

10

0
0 .0 7 9

0 .1 1 9

0 .1 5 9

Fe e d r a t e ( m m / r e v)

0 .6

(a)

0 .5

D r y cu t t in g
0 .4

Cr yoge n ic cu t t in g

30

25
0 .3

Sh e a r a n gle ( de gr e e )

Ch ip t h ick n e ss ( m m )

Cr yoge n ic cu t t in g

25

0 .2
Cu t t in g ve locit y - 5 4 m / m in ( D r y)
Cu t t in g ve locit y - 5 4 m / m in ( Cr yoge n ic)
0 .1

Cu t t in g ve locit y - 1 9 3 m / m in ( D r y)
Cu t t in g ve locit y - 1 9 3 m / m in ( Cr yoge n ic)

20

15

10

0
0

0 .0 5

0 .1

0 .1 5

0 .2

Fe e d r at e ( m m / r e v)

0 .0 7 9

0 .1 1 9

0 .1 5 9

Fe e d r a t e ( m m / r e v)

Fig. 5. Variation in chip thickness with feed rates under dry and
cryogenic machining of AISI 1045 steel.

(b)

0 .6

Fig. 7. Shear angle vs. feed rate at different cutting velocities for
AISI 1045 steel (a) 54 m/min (b) 193 m/min.

0 .5

Ch ip t h ickn ess ( m m )

0 .4

D r y cut t in g

Cr yoge n ic cut t in g

25

0 .3
20

She a r a ngle ( de gre e )

0 .2
Cu t t in g ve locit y - 5 4 m / m in ( D r y)
Cu t t in g ve locit y - 5 4 m / m in ( Cr yogen ic)
0 .1
Cu t t in g ve locit y - 1 9 3 m / m in ( D r y)
Cu t t in g ve locit y - 1 9 3 m / m in ( Cr r ogen ic)

15

10

0
0

0 .0 5

0 .1

0 .1 5

0 .2

Fe ed r a t e ( m m / r e v)

Fig. 6. Variation in chip thickness with feed rates under dry and
cryogenic machining of Aluminium 6061 T6 alloy.

0 .0 7 9

0 .1 1 9

0 .1 5 9

Fe e d ra t e ( m m / r e v)

(a)

D. Influence of Cryogenic Cooling on Shear Angle

D r y cut t in g

Cr yoge n ic cut t in g

25

The comparisons of shear angle for AISI 1045

steel and Aluminium 6061-T6 alloy with feed rates for
different cutting velocities under dry and cryogenic
cutting were shown in Figures 7(a&b) and 8 (a&b)
respectively. When comparing the shear angle under
cryogenic machining with dry machining, it was seen that
cryogenic machining results in increased shear angle.
This is due to the reduction in cutting temperature by
cryogenic cooling. The results indicate that the shear
angle was increased to a maximum of 15% and 30% in
cryogenic machining of AISI 1045 steel and Aluminium
6060-T6 alloy respectively. The increase in shear angle
will reduce the plane of shear there by reducing the chip
thickness.

Sh e a r a ngle ( de gr e e )

20

15

10

0
0 .0 7 9

0 .1 1 9

0 .1 5 9

Fe e d ra t e ( m m / r e v)

(b)
Fig. 8. Shear angle vs. feed rate at different cutting velocities for
Aluminium 6061-T6 alloy (a) 54 m/min (b) 193 m/min.

V. CONCLUSION
Experiments on orthogonal cutting of AISI 1045
steel and Aluminium 6061-T6 alloy were carried out

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International Journal of Recent Trends in Engineering, Vol. 1, No. 5, May 2009

under dry and cryogenic conditions. The major

conclusions from this investigation can be summarized as
follows:
1.

2.

3.

4.

REFERENCES

Cryogenic cooling reduced the cutting

temperature by 19-40% depending upon the
level of process parameters and work material.
The reduction in temperature using cryogenic
cooling by liquid nitrogen was high at lower
level cutting parameters and low at high level
cutting parameters.
The influence of cryogenic cooling increases the
cutting force to a maximum of 15% and 10% for
the machining of AISI 1045 steel and
Aluminium 6061-T6 alloy respectively.
Cryogenic machining with liquid nitrogen jet
reduces the chip thickness up to 25% over dry
machining.
The shear angle in cryogenic machining was
increased up to 30%.

It is evident from that experimental investigation, the

machinability characteristics of AISI 1045 steel and
Aluminium 6061-T6 alloy have shown better results in
cryogenic machining over dry machining.

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2009 ACADEMY PUBLISHER

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