Evaluation of Sustainability and Cost Effectiveness of Using LCO 2 as Cutting Fluid in Industrial Hard-Turning Installations

Iñigo Llanos (), Iker Urresti Espilla, David Bilbatua and Oier Zelaieta
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Iñigo Llanos: Ideko Research Centre, Arriaga Industrialdea 2, E-20870 Elgoibar, Spain
Iker Urresti Espilla: Ideko Research Centre, Arriaga Industrialdea 2, E-20870 Elgoibar, Spain
David Bilbatua: Danobat S. Coop., Arriaga Industrialdea 21, E-20870 Elgoibar, Spain
Oier Zelaieta: Ideko Research Centre, Arriaga Industrialdea 2, E-20870 Elgoibar, Spain

Sustainability, 2024, vol. 16, issue 22, 1-15

Abstract: Conventional oil-based emulsions used in hard-turning processes present significant environmental and economic challenges, including high waste generation and hazardous disposal requirements. In response, cryogenic CO 2 cooling has gained attention as a sustainable alternative, offering improved productivity, reduced tool wear and a diminished environmental footprint. While technical advances have been reported, the industrial adoption of cryogenic cooling is still limited due to the lack of clear data on its actual viability. This paper moves beyond the analysis of the technical performance of cryogenic CO 2 cooling analyzed in previous works to conduct a detailed evaluation of its environmental and economic performance when machining roller bearing components with pCBN tools on a hard-turning installation. Utilizing Life Cycle Assessment (LCA) and Return-on-Investment (ROI) methodologies, this study compares cryogenic CO 2 with traditional cooling methods, quantitatively assessing the environmental impact and economic viability across different manufacturing scenarios. The findings reveal that cryogenic cooling can outperform conventional cooling regarding both environmental impact and cost-effectiveness thanks to the tool life improvements provided by cryogenic cooling, specifically in cases where high tool consumption is generated during hard-turning operations. These results provide critical insights for selecting cooling strategies during the design phase of industrial turnkey projects, highlighting the potential of cryogenic CO 2 as a superior solution for sustainable and efficient hard-turning operations.

Keywords: cryogenic machining; life cycle assessment; return on investment (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2024
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