A Review of Effect of Deep Cryogenic Treatment on Cutters ... · Heat treatment applied ... the...

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A Review of Effect of Deep Cryogenic Treatment on

Cutters/Tools

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Table of Contents

Abstract ......................................................................................................................................................... 3

Introduction .................................................................................................................................................. 4

CRYOGENIC TREATMENT .............................................................................................................................. 5

CRYOGENIC SYSTEM ...................................................................................................................................... 5

TYPES OF COOLING SYSTEM ......................................................................................................................... 6

PREVIOUS WORK ........................................................................................................................................... 6

Studies on Titanium ...................................................................................................................................... 6

Studies of Wear resistant .............................................................................................................................. 8

CONCLUSIONS AND FUTURE DIRECTIONS .................................................................................................. 10

REFERENCES ................................................................................................................................................ 12




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Abstract

Face milling cutters/tools is nothing but titanium, aluminium, coal but yet there is an inconclusive aspect

with respect to wear resistant, titanium and tungsten carbide, liquid nitrogen. Therefore, the review

discovers the previous studies those are conducted on titanium, stainless steel, and wear resistant

specifically focusing on deep cryogenic treatment. Further, the review also briefly introduces the

concept of deep cryogenic and its cooling system. Finally, the review would conclude with the gaps

prevailing in the previous studies and provide recommendations for future studies.

Keywords: Cryogenic treatment; Deep; Tool/steel; face milling, wear resistant, cutting tools;




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Introduction

The word “cryogenic” originates from the Greek word “krys” which means cold. Heat treatment applied

at unconventionally low temperatures is referred to as cryogenic (Akincioğlu et al., 2015). This

treatment has been given different names in different sources such as cryo, deep cryogenic treatment,

cryogenics, cryo processing are some of the sources. Cryogenic treatment began to be used in the late

sixteenth century to enhance the mechanical properties of materials.

Generally, the concept of cryogenics denotes the science that deals with very low temperatures.

However, this has not been particularly specified and could be indicated to the temperatures lesser than

120 K which is the air’s boiling point (Timmerhaus & Reed, 2007) or is 100 K (Karassik et al., 2008).

Normally typical cryogens which is in the mode of liquid gases and could be called as liquid nitrogen

(LN2), helium (LHe), oxygen, ethane, methane and argon. Yet, in machining, at times temperatures more

than100 K would also be stated by some authors as cryogenics, for instance, cryogenic machining that

uses solid carbon dioxide and/or liquid (Machai & Biermann, 2011; Abele & Schramm, 2008; De Chiffre

et al., 2007) and even chilled air at very low temperatures (Yalcin et al., 2009; Tsai & Hocheng, 1998).

In reality, there are major differences between the treatments performed at different temperatures and

with different cycles. Consider the case of the treatments performed at -84 °C and at -196 °C. The

improvement in wear resistance is less in the former than the later. Whatever may be the scope of

treatment, the purpose remains the same, i.e. to increase the hardness of surface, wear resistance, and

toughness of the cutting tool. It has been reported that cryogenic treatment assists in increasing the

wear resistance of steels while its implementation through cutting tools. This being the reason;

numerous studies have been conducted to evaluate the resistance power and its longevity of cutting

tools treated with cryogenic materials. For instance, the study by Mohan Lal et al. (XX) where they

examined the improvement in wear resistance and the significance of treatment parameters in the

various tool and died materials. It was identified that cryogenic treatment induces approximately 110%

improvement in tool life.

Scientific studies have revealed that cryogenic treatment applied to cutting tools improves mechanical

properties such as workpiece surface roughness, homogeneous carbide distribution, hardness, and

toughness. However, sufficient information about the application of cryogenic treatment to cutting tools

lacks especially with specific reference to deep cryogenic treatment. In addition, the cryogenic

processing application system has a high initial investment cost, which is a disadvantage in terms of the

applicability of the process. Various gases such as helium, oxygen, nitrogen, and neon are used for

cryogenic treatment [74, 79, and 80]. Nitrogen constitutes a significant portion (78.03 %) of the

atmosphere, and liquid nitrogen, the most commonly used gas in cryogenic treatment applications

(Kalia, 2010; Firouzdor et al., 2008; Thakur et al., 2008).

Although there is sufficient literature available, still it is not clear whether deep cryogenic treatment

enhances the wear resistance of some specific steels as studies conducted elsewhere significantly

focused on general cryogenic treatment. Therefore, this review aimed to explore the studies conducted

on deep cryogenic treatment and identify the gap for the future studies. The paper is structured as




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follows: section 2 introduces the concept of cryogenic treatment and deep cryogenic treatment while

this is followed by the cryogenic system and types of cooling system (Section 3). Section 4 critically

reviews the previous studies conducted elsewhere on deep cryogenic treatment. Finally, the section

summarizes the findings and conclude the paper.

Cryogenic Treatment

The liquid nitrogen that is generated from the nitrogen plant is kept in storage vessels. Then, transfer

lines are used to direct the same to a closed vacuum evacuated chamber that is known as cryogenic

freezer with the help of a nozzle. The supply of liquid nitrogen into the cryo-freezer is subjected to

operation with the help of solenoid valves. The gradual takes place inside the chamber at a rate of 2º C

/min from the room temperature to a temperature of -196º C. Once it attains the sub-zero temperature,

specimens are transferred to the nitrogen chamber or soaking chamber, in which they are stored for 24

hours while supplying liquid nitrogen continuously. There are three significant elements of the cryogenic

treatment process, as obtained from the research conducted in the Mechanical Engineering Department

at Louisiana Tech University. Those elements are a very slow cool down from ambient temperature to

cryo generic temperature, a long soak at cryogenic temperatures, and a triple heat temper after the

cryogenic treatment.

CRYOGENIC SYSTEM

A cryogenic system is an equipment that allows cooling temperature, (i.e. cooling and heating rate),

specifically cooling in the cryogenic range in a chamber using cryogenic fluid like liquid helium or

nitrogen. During The sixties, Cryogenic treatment was done by direct immersion into liquid nitrogen,

which produced a catastrophic result of cracking the components. But later, the cryogenic treatment

system developed by Ed Busch (Cryo-Tech, Detroit, MI) in the late 1960‘s and later improved by Peter

Paulin with a temperature feedback control on cooling and heating rate which, prevented sudden

temperature changes and led to the development of efficient CT process.

Deep cryogenic treatment is an economical permanent treatment that impacts the mechanical aspects

of the steel components. The percentage of retained austenite contained by the conventional treatment

of steel is lessened by the process of deep cryogenic treatment. The elimination of retained austenite

and the cleansing of carbide particles are the main causes of the wear resistance enhancement. By using

deep cryogenic treatment method, the fragments are slowly cooled from room temperature to _196_C

and are soaked for around 12 to 24 hours at _196_C, and later reheated slowly again to the room

temperature continued by tempering. Charles and Arunachalam (2003) indicated that the cryogenic

treatment is a homogenous process and needs to be conducted only once that offers major significance

in the productive and functional life of steel components such as gears, engines, machine parts, brake

rotors, and transmission to gun barrels, machine tools.




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TYPES OF COOLING SYSTEM

There are three types of cryogenic cooling systems that are commonly used Gradual Immersion, Direct

Nebulization, and Heat Exchanger. Out of these three processes, the concept of third procedure of

cooling system is generally used widely. Liquid nitrogen is allowed to flow from the storage tank through

inlet pipe and allowed to enter into the cryogenic chamber (also called as Cryoprocessor-box).

Temperature is controlled through computer programming software Delta TTM, and desired cooling

rate can be set. The cooling effect is provided by LIN to the sample, but no direct contact is allowed,

among them. A fan is used for uniform distribution of temperature inside the chamber. After reaching

the temperature set by programmer thermocouple sends a signal to the system controller, through a

feedback mechanism, and hence, temperature controller regulates the flow of LIN in the chamber and

stop further cooling. The LIN gets converted and leaves the system as nitrogen gas (Dhar et al., 2001).

PREVIOUS WORK

Several studies have been conducted previously on deep cryogenic treatment

Hong and Ding (2001) identifying the cooling approach for most effectively and economically using

cryogenic machining. This study evaluated cutting temperatures obtained under various cooling

conditions where study applied liquid nitrogen (LN2) to cut Ti-6Al-4V, a difficult-to-machine. Dhar et al.

(2002) performed a study by applying the LN2 jet while turning of AISI 4140 steel in the cutting zone and

found higher surface roughness, limited tool wear and high dimension of accuracy when compared to

dry and wet machining. Stewart (2004) conducted cryogenic treatment into C2 tungsten carbide (WC-6%

Co) inserts and correlated to untreated carbide inserts in a medium density fibreboard (MDF). Reddy et

al. (2008) determined the impact of deep cryogenic treatment over the chemical vapor deposition (CVD)

coated over carbide ISO P-30 inserts in the machining process of C45 steel. Arrazola et al. (2009)

evaluated a tool wear mechanisms when machining Ti555.3. Vadivel and Rudramoorthy (2009) in the

turning of nodular cast iron evaluated the microstructure of cryogenically treated (TiCN+A12O3) and the

untreated inserts and found that the treated and coated carbide inserts had better significance that

untreated (UT) carbide tools.

Studies on Titanium

This section reviews the specific studies on the effect of deep cryogenic treatment on Titanium.

Gill et al. (2011) enhanced the effects of shallow and deep cryo-treated carbide tools in C-65 steel

turning. Based on preliminary turning tests, the cutting speed was varied in four increments: 110,

130, 150, and 180 m/min. All the cutting tests were performed at a feed rate of 0.1 mm/rev and

depth of cut of 1 mm. The cryogenic treatment appeared to be effective in reducing surface roughness

for relatively longer machining times. Cryogenic treatment causes crystal structure changes in both the




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hard and soft binder phase of tungsten carbide which, along with the precipitation of phase carbides,

may have been responsible for the enhanced cutting life of the cutting inserts.

Armendia et al. (2012) examined that single-point tool life analysis and a Orthogonal cutting force

measurements to evaluate the response to heat treatment by machining on three titanium alloys

namely Ti6246, Ti-5Al-4V-0.6Mo-0.4Fe (TIMETAL1 54M) and Ti6Al4V. The TIMETAL154M indicated

higher performance than the regular Ti6A14V of a tool life of 15 minutes with a 20% maximized

allowable cutting speed. The Ti6246 alloy indicated the highest cutting forces and higher tool wear rates

in various heat treatment settings due to its durable mechanical properties. A recently developed allow

with identical mechanical properties of Ti6A14V called the TIMETAL1 54M alloy, indicated lower wear

rates. In machining of alloys, there had been microstructural variations as an effect of heat treatment.

The b annealed samples of the When TIMETAL1, and Ti6A14V 54M alloys were taken and b annealed,

with a fine lamellar microstructure, indicated considerable high cutting forces and short tool life.

Whereas the other heat treatments indicated no major impact on the machinery behavior of the

evaluated alloys as it produced no microstructural developments. The Ti6246 alloy indicated shorter tool

life and high cutting force measurements in the tested body. The test outcomes indicated better

mechanical properties of the alloy when correlated to TIMETAL154M and Ti6A14V alloy.

Dhananchezian et al. (2011) examined the effect of LN2 cooling while turning of AISI 304 stainless steel

using modified tungsten carbide tool inserts. The effect of liquid nitrogen as a coolant applied through

holes made on the rake and flank surfaces of the PVD TiAlN coated tungsten carbide turning tool inserts

of ISO CNMG 120412 MP–KC5010 on the turning of AISI 304 stainless steel is studied. The influence of

cryogenic cooling on the cutting temperature, cutting force, surface roughness, and tool wear has been

compared with those of wet machining. It is observed that in the cryogenic cooling method, the cutting

temperature was reduced by 44–51%, the cutting force was decreased to a maximum of 16%, and the

surface roughness was reduced by 22–34% over that of wet machining. Cryogenic cooling using liquid

nitrogen reduced tool wear through the control of temperature-dependant wear mechanisms.

Senthilkumar and Rajendran (2012) illustrated a study on L27 Taguchi orthogonal design with the

parameters of deep cryogenic treatment to attain a minimum wear loss of 4140 steel. The four

identified process parameters included for the optimization study were hardening temperature (A),

soaking period (B), tempering temperature (C), and tempering period (D). The communications among

these factors are also determined. In the deep cryogenic treatment method the most important factor

was the hardening temperature at a percentage of 17.34% at 888 C. It was also determined that

interactions between the hardening temperature vs. tempering temperature (AxC) and soaking period

(2.32%) vs. tempering period (2.35%) (BxD) has been more vital than any other factors.

Ravi and Kumar (2012) organized an investigation on the impact of cryogenic cooling using liquid

nitrogen (LN2) jet in the performance of milling in hardened AISI D3 tool steel using TiN-coated carbide

inserts. The test was conducted at a stable speed of 125 m/min at three various feed rates at the range

of 0.01 to 0.02 mm/tooth. In the process of LN2 machining. The cutting temperature was limited to 43-

48% and 22-39% in dry and wet machining. The results show that machining with LN2 lowers cutting

temperature, tool flank wear, surface roughness and cutting forces as compared with dry and wet




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machining. With LN2 cooling, it has been found that the cutting temperature was reduced by 57–60%

and 37–42%; the tool flank wear was reduced by 29–34% and 10–12%; the surface roughness was

decreased by 33–40% and 25–29% compared to dry and wet machining. The cutting forces also

decreased moderately compared to dry and wet machining. This can be attributed to the fact that LN2

machining provides better cooling and lubrication through a substantial reduction in the cutting zone

temperature.

Reddy and Ghosh (2014) explores the negative side of cryo technology in a case study, where hardened

bearing steel (AISI 52100) was ground by an alumina wheel with chilled N2 in both gas and liquid (LN2)

jet form. Elemental analysis of the sample was carried using Optical Mission Spectroscope (OES) -196 is

the temperature. The machine tool used is Reciprocating surface grinder. It was observed that the

ground specimen suffered a significant dimensional deviation with the liquid jet with respect to dry and

soluble oil environment. In a similar fashion, microhardness of workpiece notably was changed and so

was the deterioration of surface finish. On the contrary, G-ratio was found to be remarkably improved,

which is in line with information about the available literature. The extent of those adverse effects could

be controlled by using chilled N2 gas instead of LN2 jet however with a compromise on G-ratio.

In this Gill et al. (2011) discussed the enhanced the tool life in the interrupted machine under the

cooling conditions. Armendia et al. (2012) examined about the single point analysis of the orthogonal

cutting. Senthilkumar and Rajendran (2012) studies on L27 Taguchi orthogonal design with the

parameters of deep cryogenic treatment to attain a minimum wear loss. Dhananchezian et al. (2011)

also studied about the LN2 cooling but by using the tool AISI 304. Ravi and Kumar (2012) impact of

cryogenic cooling using liquid nitrogen (LN2) jet in the performance of milling in hardened AISI D3 tool

steel using TiN-coated carbide inserts. Reddy and Ghosh (2014) explores the negative side of cryo

technology in a case study, where hardened bearing steel (AISI 52100) was ground by an alumina wheel

with chilled N2 in both gas and liquid (LN2)

Studies of Wear resistant

This section reviews the studies on deep cryogenic treatment on wear resistant. Kaushal et al. (2015)

evaluated about Micro- structure and Hardness, after Cryogenic treatment comparison is also made

with untreated test specimen. The study adopted temperature of about – 196 by using the tool steel

AISI- D2. The study findings revealed that hardness increased after cryogenic treatment in comparison

with untreated also change in the microstructure was observed due to phase transition from austenite

to martensite which also altered the various properties of tool AISI-D2 steel.

Jandová et al. (2015) investigated the impact of a deep cryogenic treatment on the wear resistance and

microstructure of the X37CrMoV5-1 (H11) hot-work steel. The wear resistance was measured at 400 °C

using the pin-on-disc method with a rotary tribometer. The microstructure of the steel was examined

using light and transmission electron microscopes. The study findings revealed that a microstructural

observation in a light microscope did not reveal any substantial differences between the specimens

hardened in the conventional manner and the specimens after a deep cryogenic treatment. On the




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other hand, the analysis of specimens upon deep cryogenic treatment by means of transmission

electron microscopy found two types of substructure, which are likely to facilitate the precipitation of

fine carbides during the final tempering of the steel. At this point, the impact of longer holding times at

the deep cryogenic temperature on this substructure has not been analyzed. The cause of the decline in

the wear resistance with extended holding times cannot thus be determined.

Ather and Sonawane (2015) aimed to reveal the enhancement of wear resistance of AISI D3 Tool Steel

by Cryogenic Treatment. In the experimentation process, samples of AISI D3 tool steel were taken in

batches out of which some samples were treated with conventional heat treatment (QT) whereas other

were cryogenically treated (QCT) at 77 K for a period of 24 hrs. The study findings revealed that there is

an increase in wear resistance of AISI D3 material after performing the cryogenic treatment. Yet, this

increase varied from few percent too few hundred percentage. Therefore depending upon the load

conditions, cryogenic treatment should carry out or not.

In this Jandová et al. (2015) investigated procedure and the results of exploring the impact of a deep

cryogenic treatment on the wear resistance and microstructure of the X37CrMoV5-1.

Ather and Sonawane (2015) revealed the enhancement of wear resistance of AISI D3 Tool Steel by

Cryogenic Treatment. Kaushal et al. (2015) evaluated about Micro- structure and Hardness, after

Cryogenic treatment comparison is also made with untreated test specimen.

Author, Year Objective Tools Sample Cryogenic temperature and period Results Dhananchezian et al.

(2011) effect of LN2 cooling while turning of AISI 304 stainless steel using modified tungsten carbide tool

inserts TiAlN coated tungsten carbide turning tool Titanium 304. It is observed that in the cryogenic

cooling method, the cutting temperature was reduced by 44–51%, the cutting force was decreased to a

maximum of 16%, and the surface roughness was reduced by 22–34% over that of wet machining Gill et

al. (2011) the effects of shallow and deep cryo-treated carbide tools in C-65 steel turning deep

cryo-treated carbide Titanium 110, 130, 150, and 180 m/min Enhanced tool life in interrupted

machining under cooling conditions.

Senthilkumar and Rajendran (2012)

L27 Taguchi orthogonal design to attain a minimum wear loss L27 Titanium 888 Interactions between

the hardening temperature vs. tempering temperature (AxC) and soaking period (2.32%) vs. tempering

period (2.35%) (BxD) has been more vital than any other factors.

Armendia et al. (2012)

single-point tool life analysis and an Orthogonal cutting force measurements Ti6246, Ti-5Al-4V-

0.6Mo-0.4Fe (TIMETAL1 54M) and Ti6Al4V Titanium 54M of 15 minutes Ti6246 alloy indicated the

highest cutting forces and higher tool wear rates in various heat treatment settings due to its durable

mechanical properties




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Ravi and Kumar (2012)

the impact of cryogenic cooling using liquid nitrogen (LN2) jet in the performance of milling AISI D3

Titanium 43-48% and 22-39% in dry and wet machining the cutting temperature was reduced by 57–

60% and 37–42%; the tool flank wear was reduced by 29–34% and 10–12%; the surface roughness was

decreased by 33–40% and 25–29% compared to dry and wet machining.

Reddy and Ghosh (2014)

Negative side of cryo technology in a case study AISI 52100 OES -196 ground specimen suffered a

significant dimensional deviation with the liquid jet with respect to dry and soluble oil environment

Kaushal et al. (2015)

Micro- structure and Hardness, after Cryogenic treatment comparison AISI- D2 Wear resistant -196

hardness increases after cryogenic treatment in respect of untreated as well as Micro- structure is also

changed due to a phase transition

Jandová et al. (2015)

investigation procedure and the results of exploring the impact of a deep cryogenic treatment on the

wear resistance X37CrMoV5-1 wear resistance 400 for 6 hours microstructural observation in a light

microscope did not reveal any substantial differences between the specimens hardened in the

conventional manner and the specimens after a deep cryogenic treatment

Ather and Sonawane (2015)

The enhancement of wear resistance of AISI D3 Tool Steel by Cryogenic Treatment. AISI D3 Wear

Resistance 77 K for a period of 24 hours There is an increase in wear resistance of AISI D3

material after performing the cryogenic treatment.

CONCLUSIONS AND FUTURE DIRECTIONS

Overall studies reviewed had focused to (Gill et al., 2011) enhance the tool life in interrupted machine

under the cooling conditions, single point analysis of the orthogonal cutting (Armendia et al. 2012), L27

Taguchi orthogonal design with the parameters of deep cryogenic treatment to attain a minimum wear

loss. (Senthilkumar & Rajendran, 2012), LN2 cooling but by using the tool AISI 304, (Dhananchezian et

al., 2011), and performance of milling in hardened AISI D3 tool steel using TiN-coated carbide inserts

(Ravi and Kumar (2012)., enhancement of wear resistance of AISI D3 Tool Steel (Ather & Sonawane,

2015), and Micro- structure and Hardness (Kaushal et al., 2015) evaluated about, after Cryogenic

treatment comparison is also made with untreated test specimen. In addition, studies also examined

the Further studies negative side of cryo technology in a case study, where hardened bearing steel (AISI

52100) was ground by an alumina wheel with chilled N2 in both gas and liquid (LN2) (Reddy & Ghosh,




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2014) while few investigated procedure and the results of exploring the impact of a deep cryogenic

treatment on the wear resistance and microstructure of the X37CrMoV5-1 Jandová et al. (2015)

From the review, it is found that cryogenic is applied to wear resistant, titanium, stainless steel and for

metallurgical analysis. In future, the cryogenic can be applied to other components like gears, shaft and

springs to improve their performance. In addition, it is observed that only a few reviews were made by

considering CVD, OEM. The future work can also be done by considering tungsten carbide, HSS, PVD,

CVD and OEM




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