Towards specific cutting energy analysis in the machining of Inconel 601 alloy under sustainable cooling conditions

Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Yilmaz, Hakan; Ross, Nimel Sworna; Boy, Mehmet; Sivalingam, Vinoth Kumar; Chan, Choon Kit; Raman, Jeyagopi

doi:10.1016/j.jmrt.2023.10.192

Cited by 13 publications

(1 citation statement)

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“…The cutting force is an essential machinability indicator for determining the loads and stress on tool and power consumption, and tool wear and surface integrity deteriorate when high [6,13]. At this point, MQL and nano-MQL cutting environments provide significant positive benefits on machinability outputs MQL cutting environments provide significant positive benefits on machinability outputs such as cutting forces, specific cutting energy, and tool wear compared to dry cutting in turning or milling applications [14][15][16]. This aligns with the nomenclature of the procedure, indicating that it pertains to the MQL method.…”

Section: Introductionmentioning

confidence: 99%

Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments

Günay,

Korkmaz

2024

Materials

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Although chip morphology changes according to the machining method and related cutting parameters, chip formation affects the quality of the machined surface. In this context, it is very important to understand the relationship between chip morphology and surface quality, especially in materials that are difficult to machine. In the presented study, the changes in chip morphology, surface morphology, and surface quality criteria (Ra and Rz) that occurred during the milling of precipitation-hardened steel in different cutting environments were analyzed. Milling experiments were carried out in dry, MQL (minimum quantity lubrication), nano-MQL (graphene), nano-MQL (hBN), Cryo, and Cryo-MQL environments using TiAlN-coated inserts and three different cutting speeds and feed rates. While the highest values in terms of Ra and Rz were measured in dry machining, the minimum values were obtained in a nano-MQL (hBN) cutting environment. Due to the lubrication and low friction provided by the MQL cutting environment, chips were formed in thinner segmented forms. This formation reduced the chip curve radius and thus provided a more stable surface morphology. On the other hand, Cryo-ambient gas could not effectively leak into the cutting zone due to the intermittent cutting process, but it increased the brittleness of the chips with the cooling effect and provided a similar surface morphology. The values of minimum Ra and Rz were obtained as 0.304 mm and 1.825 mm, respectively, at a 60 m/min cutting speed and 0.04 mm/rev feed. Consequently, the use of nano-MQL cutting medium is seriously recommended in terms of surface quality in milling operations of difficult-to-machine materials.

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