Optimization of Parameters and Sustainability Assessment Under Minimum Quantity Solid Lubrication-Assisted Machining of Inconel 718

• Published in: Process integration and optimization for sustainability 2021-09, Vol.5 (3), p.625-644
• Main Authors: Makhesana, M. A., Patel, K. M.
• Format: Article
• Language: English
• Subjects: Carbon; Cooling; Corrosion fatigue; Corrosion resistance; Cutting fluids; Cutting parameters; Cycle time; Decision making; Dry machining; Economics and Management; Emissions; Energy conservation; Energy consumption; Energy Policy; Engineering; Environmental impact; Fatigue strength; Heat conductivity; Industrial and Production Engineering; Industrial Chemistry/Chemical Engineering; Lubricants & lubrication; Lubrication; Machinability; Manufacturing; Molybdenum; Molybdenum disulfide; Nanoparticles; Nickel; Nickel alloys; Nickel base alloys; Occupational health; Optimization; Optimization techniques; Original Research Paper; Power consumption; Process parameters; Solid lubricants; Superalloys; Surface roughness; Sustainability; Sustainable Development; Taguchi methods; Temperature; Titanium alloys; Tool life; Tool wear; Vegetable oils; Waste Management/Waste Technology
• ISSN: 2509-4238; 2509-4246
• DOI: 10.1007/s41660-021-00171-w

The nickel-based alloys are well-acknowledged for their high tensile and fatigue strength, good toughness, corrosion resistance, etc. However, the machinability of it is a difficult task that can be improved with sustainable cooling/lubrication strategies. Looking at the harmful effects of conventional cutting fluids on the health of workers and the environment, this study aims to evaluate the effectiveness of minimum quantity solid lubrication (MQSL). To improve minimum quantity lubrication performance (MQL), molybdenum disulfide (MoS 2 ) is used for MQSL application. For optimizing machining parameters, the Grey Relational Analysis coupled with the Taguchi method has been utilized by measuring surface roughness, power consumption, chip–tool interface temperature, and tool wear. The validation of the obtained optimum process parameters is done by performing the confirmation test. The machinability and environmental parameters such as surface roughness, tool life, total cycle time, energy consumption, and carbon emissions are analyzed under dry, wet, MQL, and MQSL conditions. In comparison with dry machining, the improvement in tool life is appeared to be 69% and 75% with MQL and MQSL, respectively. The efficacy of MQL and MQSL is seen with almost 49% and 64% saving in energy consumption and 45% and 79% reduction in carbon emission with lower values of cutting parameters to achieve overall sustainability. The approach presented here offers an effective approach to select the combination of the machining parameters with an environment-friendly lubrication approach toward the development of sustainable processes.