Low temperature hard turning technology
Cubic Boron Nitride (CBN) and Polycrystalline Cubic Boron Nitride (PCBN) tools are widely used in hard turning applications due to their excellent wear resistance and ability to machine hardened materials. However, many workshops still avoid using them because of the high cost involved. Fortunately, the emergence of cryogenic cutting technology has provided a viable alternative. This innovative approach enables high-speed hard turning without the need for expensive CBN or PCBN tools, while also significantly extending tool life.
The Icefly cryogenic cooling system, developed by Air Products in the USA, is designed to spray liquid nitrogen at -320°F directly onto the cutting tool during the machining process. The system works by rapidly lowering the temperature in the cutting zone, which helps prevent the tool from softening due to heat. As a result, the tool maintains its hardness and cutting performance for longer periods. Moreover, the low-temperature environment helps preserve the sharpness of the cutting edge, reducing the risk of chipping or damage that could otherwise harm the finished part. Additionally, the cold treatment induces compressive stress on the surface of the workpiece, improving surface quality and reducing roughness.
This cryogenic system can be integrated as an independent unit or retrofitted into existing machine tool cooling systems. For example, it has been successfully applied to lathes like the Quest series from Hardinge Corporation in New York. Liquid nitrogen is typically stored in a cylindrical tank near the machine or in a sealed oil tank. A flexible hose connects the tank to the lathe’s tool holder, delivering the liquid nitrogen through a nozzle to the cutting area. The programming required for this system is similar to that of traditional cooling methods, making it easy to implement.
According to industry reports, cryogenic cooling offers unique benefits when working with hardened steel, composite materials, and powder metallurgy parts. Since liquid nitrogen is inert and evaporates quickly upon contact, it leaves no residue behind, unlike conventional coolants. This makes it especially beneficial for processing porous or water-permeable materials, where cleaning excess coolant can be time-consuming and labor-intensive. By eliminating the need for post-processing cleaning, the technology not only improves efficiency but also enhances overall productivity.
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