Performance comparison of coated carbide tool under different cooling/lubrication environments during face milling of Inconel-625 and Stainless Steel 304

• Published in: World journal of engineering 2019-05, Vol.16 (2), p.287-295
• Main Authors: Singh, Pragat, Dureja, J.S, Singh, Harwinder, Bhatti, Manpreet S
• Format: Article
• Language: English
• Subjects: Abrasion; Aerospace industry; Aircraft industry; Alloy steels; Aluminum base alloys; Austenitic stainless steels; Carbide cutting tools; Carbide tools; Chromium base alloys; Cooling; Cutting fluids; Dry machining; Failure modes; Floods; Fluids; Fracture mechanics; Heat conductivity; Heat transfer; Inserts; Lubricants & lubrication; Lubrication; Machine tools; Mechanical properties; Metal cutting; Milling (machining); Nanoparticles; Nickel base alloys; Researchers; Scanning electron microscopy; Stainless steel; Steel alloys; Strain hardening; Tensile strength; Thermal conductivity; Titanium alloys; Titanium base alloys; Turbine blades; Vegetables; Work hardening
• ISSN: 1708-5284; 2515-8082
• DOI: 10.1108/WJE-06-2018-0194

Purpose This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys). Design/methodology/approach Machining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy. Findings The results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life. Research limitations/implications Inconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions. Originality/value The literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly m