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<p>Ti-6Al-4V titanium alloy is prone to high temperatures and poor machinability during processing. To address this, a novel system combining supercritical CO<sub>2</sub> (ScCO<sub>2</sub>) cooling and electrostatic minimum quantity lubrication (EMQL), termed ScCO<sub>2</sub>–EMQL, was applied to its milling. This system generates a low-temperature, charged spray, significantly improving cutting zone cooling and lubrication. This study investigated how voltage, air pressure, flow rate, and nozzle distance affect the ScCO<sub>2</sub>–EMQL spray’s charge-to-mass ratio and droplet size, as well as its heat transfer enhancement. The charge-to-mass ratio positively correlates with voltage and air pressure, but negatively with flow rate and nozzle distance. Conversely, droplet size negatively correlates with voltage and air pressure, but positively with flow rate and nozzle distance. Charged droplets under − 6&#xa0;kV improved transient heat transfer by 8.65% and steady-state heat transfer by 4.61% compared to uncharged droplets. Further milling performance studies on Ti-6Al-4V revealed that ScCO<sub>2</sub>–EMQL reduced cutting temperatures by 51.03, 44.74, 7.21, and 1.89% compared to dry cutting, EMQL, ScCO<sub>2</sub>, and supercritical CO<sub>2</sub> minimum quantity lubrication (ScCO<sub>2</sub>–MQL), respectively. Crucially, compared to ScCO<sub>2</sub>–MQL, ScCO<sub>2</sub>–EMQL reduced tool flank wear by 9.5%, decreased cutting force by 13.1%, and extended tool life by 12.5%. This demonstrates ScCO<sub>2</sub>–EMQL as a highly efficient cooling and lubrication technology.</p>

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Milling Performance of Ti-6Al-4V Titanium Alloy under Supercritical CO2 with Electrostatic Minimum Quantity Lubrication

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Xiaodong Hu,
  • Zongkun Sun,
  • Chao Chen,
  • Xuefeng Xu,
  • Ruochong Zhang

摘要

Ti-6Al-4V titanium alloy is prone to high temperatures and poor machinability during processing. To address this, a novel system combining supercritical CO2 (ScCO2) cooling and electrostatic minimum quantity lubrication (EMQL), termed ScCO2–EMQL, was applied to its milling. This system generates a low-temperature, charged spray, significantly improving cutting zone cooling and lubrication. This study investigated how voltage, air pressure, flow rate, and nozzle distance affect the ScCO2–EMQL spray’s charge-to-mass ratio and droplet size, as well as its heat transfer enhancement. The charge-to-mass ratio positively correlates with voltage and air pressure, but negatively with flow rate and nozzle distance. Conversely, droplet size negatively correlates with voltage and air pressure, but positively with flow rate and nozzle distance. Charged droplets under − 6 kV improved transient heat transfer by 8.65% and steady-state heat transfer by 4.61% compared to uncharged droplets. Further milling performance studies on Ti-6Al-4V revealed that ScCO2–EMQL reduced cutting temperatures by 51.03, 44.74, 7.21, and 1.89% compared to dry cutting, EMQL, ScCO2, and supercritical CO2 minimum quantity lubrication (ScCO2–MQL), respectively. Crucially, compared to ScCO2–MQL, ScCO2–EMQL reduced tool flank wear by 9.5%, decreased cutting force by 13.1%, and extended tool life by 12.5%. This demonstrates ScCO2–EMQL as a highly efficient cooling and lubrication technology.