Environment Friendly Machining of Ni–Cr–Co Based Super Alloy using Different Sustainable Techniques

Abstract

In order to eradicate the use of mineral based cutting fluid, the machining of Ni-Cr-Co based Nimonic 90 alloy was conducted using environment friendly sustainable techniques. In this work, uncoated tungsten carbide inserts were employed for the machining under dry (untreated and cryogenically treated), MQL and cryogenic cutting modes. The influence of all these techniques was examined by considering tool wear, surface finish, chip contact length, chip thickness and chip morphology. It was found that the cryogenically treated tools outperformed the untreated tools at 40 m/min. At cutting speed of 80 m/min, MQL and direct cooling with liquid nitrogen brought down the flank wear by 50% in comparison to dry machining. Similarly at higher cutting speed MQL and cryogenic cooling techniques provided the significant improvement in terms of nose wear, crater wear area and chip thickness value. However, both dry and MQL modes outperformed the cryogenic cooling machining in terms of surface roughness value at all the cutting speeds. Overall cryo treated tools was able to provide satisfactory results at lower speed (40 m/min). Whereas both MQL and cryogenic cooling method provided the significantly improved results at higher cutting speeds (60 m/min and 80 m/min) over dry machining.

Some investigations in grindability improvement of Inconel 718 under ecological grinding

“…Ni-based superalloys are one of such superalloys getting broad appreciation and being used throughout the world due to their superior mechanical properties. [19][20][21][22] IN718, an Ni-based superalloy, was invented in the 1950s. 20 It happens to be an attractive material for many engineering applications with a production rate of almost 50% of all superalloys in the world.…”

A Combined Experimental and Optimization Model to Improve the Machinability of Nimonic C-263 Superalloy

“…studied the effect of cryogenically treated inserts (indirect technique) with different soaking duration at different temperatures to achieve improved machined surface quality [7,24,26,29]. Similarly, few studies report impingement of cryogenic liquid on the machining zone (direct technique) can enhance the performance of the process [8][9][10].…”

“…The study revealed that the PVD coated tool successfully controls the tool wear for the complete range of spindle speed. [24,25,29] who examined the effects of machining environment like high pressure cooling and direct cryogenic cooling on the life of tool and surface integrity throughout the machining of workpiece. The experimental results have shown that the suggested higher-press ure cooling approach carried significant growth of tool life of 133% for PVD double layered coated tool and microcrystalline uncoated carbide inserts have maximum of 275%.…”

“…indirect cryogenics to achieve better tool life [26][27][28]. Chetan et al is the only researcher who has carried out turning process on Nimonic work piece with cryo-treated inserts till date [29]. However, tool wear has not been considered as a response in the study.…”

“…Extensive study of past literature indicates that good amount of work has been reported worldwide to enhance the performance of turning process by the researchers. Literature reports abundant works on indirect cryogenic and direct cryogenics approaches to achieve improve machinability on various combination of work-tool pair individually [24][25][26][27][28][29]. However, to the best of our knowledge, a report that evaluates the machinability of the turning process combining the hybrid strategy of both direct and indirect is extremely scarce in the literature.…”