Analysis of the influence of nitrogen phase and surface heat transfer coefficient on cryogenic machining performance

•Sustainability performance of the cryogenic machining conditions is investigated.•An innovative cryogenic fluid phase diagnostics sensor is developed and evaluated.•For the first time, the issue of nitrogen phase in cutting process is emphasized.•Phase characteristics are implemented into developed predictive performance model.•Shown is that the cryogenic phase significantly affects machining of Inconel 718 alloy.

This paper presents the influence of the nitrogen fluid phase on the surface heat transfer coefficient in cryogenic machining. A novel optical nitrogen phase sensor was developed for characterizing the cryogenic fluid phase. Surface heat transfer coefficients were established experimentally by using a new heat transfer model for cryogenic machining. A finite element model was developed utilizing experimental data for Inconel 718. Using it, the process behavior with varying nitrogen phases was simulated. Determining the minimal, but sufficient amount of coolant flow-rate, in combination with the desired fluid phase at the delivery, was found to be the key for achieving truly sustainable cryogenic machining.