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<p>Ti–6Al–4V is widely used in aerospace and biomedical applications, but its poor thermal conductivity leads to excessive heat generation, rapid tool wear and residual stress during machining. This study presents a coupled CFD–FE simulation approach to investigate the thermo-mechanical behavior of Ti–6Al–4V in turning under CO<sub>2</sub>-based Dual Nozzle Vortex Tube (DNVT) cooling. A computational fluid dynamics (CFD) model was developed to evaluate the flow dynamics and heat transfer characteristics, which were used as boundary conditions in finite element (FE) model of the machining process. This integrated CFD–FE model was validated experimentally and used to analyze the influence of machining, coolant and nozzle parameters on cutting force, temperature and residual stress. The model demonstrated that higher coolant pressure and cold fraction significantly enhanced cooling efficiency and induced favorable compressive residual stresses. However, the cutting force is increased due to the impulse of the high velocity jet stream. Similarly, cutting speed, feed and depth of cut show distinct and interdependent effect with feed rate emerged as the most influential factor on both cutting force and residual stress formation. CO<sub>2</sub>-DNVT cooling effectively reduced cutting temperature by 26.5% compared to dry cutting. However, it resulted in increase of cutting force by 18.26% due to the impulse force generated by high velocity CO<sub>2</sub> jet stream. The use of CO<sub>2</sub>-DNVT cooling led to the transformation of residual stress tensile to compressive in nature.</p>

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Thermo-Mechanical Modeling and Simulation of Ti–6Al–4V Machining with CO2 Cooling

  • 期刊论文

  • 发表日期：

    2025年11月3日

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  • Banoth Srinu,
  • Maroju Naresh Kumar,
  • Srimanthula Srikanth,
  • Vamsi Krishna Pasam,
  • Venu Gopal Anne

摘要

Ti–6Al–4V is widely used in aerospace and biomedical applications, but its poor thermal conductivity leads to excessive heat generation, rapid tool wear and residual stress during machining. This study presents a coupled CFD–FE simulation approach to investigate the thermo-mechanical behavior of Ti–6Al–4V in turning under CO2-based Dual Nozzle Vortex Tube (DNVT) cooling. A computational fluid dynamics (CFD) model was developed to evaluate the flow dynamics and heat transfer characteristics, which were used as boundary conditions in finite element (FE) model of the machining process. This integrated CFD–FE model was validated experimentally and used to analyze the influence of machining, coolant and nozzle parameters on cutting force, temperature and residual stress. The model demonstrated that higher coolant pressure and cold fraction significantly enhanced cooling efficiency and induced favorable compressive residual stresses. However, the cutting force is increased due to the impulse of the high velocity jet stream. Similarly, cutting speed, feed and depth of cut show distinct and interdependent effect with feed rate emerged as the most influential factor on both cutting force and residual stress formation. CO2-DNVT cooling effectively reduced cutting temperature by 26.5% compared to dry cutting. However, it resulted in increase of cutting force by 18.26% due to the impulse force generated by high velocity CO2 jet stream. The use of CO2-DNVT cooling led to the transformation of residual stress tensile to compressive in nature.