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<p>Enhancing the machinability of Ti-6Al-4V titanium alloy under high-speed face milling remains a significant challenge due to its low thermal conductivity and high chemical reactivity. In this study, a novel eco-efficient hybrid cooling/lubrication strategy combining dry ice (i.e., solid state CO<sub>2</sub>) assisted cooling with a pulsated minimum quantity lubrication (MQL) system was investigated. Different with conventional MQL or cryogenic approaches, the proposed system utilizes a low MQL flow rate of 35 mL/h integrated with dry ice cooling to ensure simultaneous lubrication and enhanced thermal control at the cutting interface. Milling experiments were performed under three different conditions as dry, pulsated MQL, and hybrid (pulsated MQL + dry ice) at varying cutting speeds of 100–250&#xa0;m/min) and feed rates of 0.08–0.12&#xa0;mm/z. The hybrid system’s performance was evaluated through comprehensive analysis of tool wear, cutting force, machined surface roughness and topography, phase composition, and subsurface microhardness. The results demonstrated that the hybrid environment significantly reduced tool wear and cutting forces while improving surface quality and preserving the material’s crystalline structure. Machined surface roughness <i>R</i><sub><i>a</i></sub> was reduced by up to 83% compared to dry machining, and X-ray diffraction analysis revealed minimal formation of secondary phases under hybrid conditions. Furthermore, the hybrid setup showed lower subsurface microhardness, indicating effective suppression of thermally induced strain hardening. Overall, the proposed hybrid MQL-dry ice cooling strategy proved highly effective in improving machining performance and surface integrity while aligning with sustainable manufacturing goals through reduced lubricant usage.</p>

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A Novel Hybrid Lubri-Cooling Approach for Machining of Ti-6Al-4V Through Combination of Pulsated Minimal Quantity Lubrication and Dry Ice Media

  • 期刊论文

  • 发表日期：

    2025年12月22日

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  • Muhammad Ahmed Khan,
  • Bing Wang,
  • Zhanqiang Liu,
  • Aqib Mashood Khan,
  • B. Mouli Prasanth,
  • Aisheng Jiang

摘要

Enhancing the machinability of Ti-6Al-4V titanium alloy under high-speed face milling remains a significant challenge due to its low thermal conductivity and high chemical reactivity. In this study, a novel eco-efficient hybrid cooling/lubrication strategy combining dry ice (i.e., solid state CO2) assisted cooling with a pulsated minimum quantity lubrication (MQL) system was investigated. Different with conventional MQL or cryogenic approaches, the proposed system utilizes a low MQL flow rate of 35 mL/h integrated with dry ice cooling to ensure simultaneous lubrication and enhanced thermal control at the cutting interface. Milling experiments were performed under three different conditions as dry, pulsated MQL, and hybrid (pulsated MQL + dry ice) at varying cutting speeds of 100–250 m/min) and feed rates of 0.08–0.12 mm/z. The hybrid system’s performance was evaluated through comprehensive analysis of tool wear, cutting force, machined surface roughness and topography, phase composition, and subsurface microhardness. The results demonstrated that the hybrid environment significantly reduced tool wear and cutting forces while improving surface quality and preserving the material’s crystalline structure. Machined surface roughness Ra was reduced by up to 83% compared to dry machining, and X-ray diffraction analysis revealed minimal formation of secondary phases under hybrid conditions. Furthermore, the hybrid setup showed lower subsurface microhardness, indicating effective suppression of thermally induced strain hardening. Overall, the proposed hybrid MQL-dry ice cooling strategy proved highly effective in improving machining performance and surface integrity while aligning with sustainable manufacturing goals through reduced lubricant usage.