This study investigated vortex-tube cooling for dry machining of hypereutectic silicon-aluminum alloys. Experiments and numerical analysis were employed to study vortex-tube cooling effects on tool wear and cutting temperatures. A390 alloy was machined by tungsten carbides with cutting forces and temperatures measured. Vortex-tube cooling was approximated as an impinging air jet to estimate heat convection coefficients that were then incorporated into the heat transfer analysis of cutting tool temperatures. The major findings include: (1) Vortex-tube cooling may reduce tool wear in A390 machining and the minimum temperature setting is more effective, (2) Cooling effects on tool wear also depend upon machining conditions, and (3) Tool temperature decrease due to vortex-tube cooling may indirectly result in tool wear reductions.

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