Influence of dry and solid lubricant-assisted MQL cooling conditions on the machinability of Inconel 718 alloy with textured tool

  • Chetan Darshan
  • Sumit Jain
  • Manu Dogra
  • Munish Kumar Gupta
  • Mozammel MiaEmail author
  • Raisul Haque


Machinability of Ni-based aerospace alloy is considered to be difficult due to its numerous intrinsic properties. However, the machining performance of nickel-based alloys can be improved with the geometric alteration on the tool rake zone and by the proper cooling-lubrication mechanism. However, the complete consideration of the proper mechanisms is required. To fill this gap, the impact of cutting speed, machining time, and tool texturing was thoroughly inquired about along with cooling conditions on machinability indices such as tool wear, chip morphology, and cutting forces as well as surface finish. The machining tests were done with textured tools on Inconel 718 alloy at cutting speeds 80, 120, and 180 m/min respectively. Then, the comparison of machining characteristics with or without using solid lubrication mixed minimum quantity lubrication system were made. For that, the time of cutting was restricted to 10 min for comparison purposes. For machining at 80 and 180 m/min, the noteworthy reduction in flank and crater wear was observed, whereas at 120 m/min, small reduction is seen from 1 to 10 min under NFMQL condition. The surface roughness was found to be higher under a dry environment compared to a NFMQL environment due to the low coefficient of friction of MoS2 at a constant feed rate with an increase in cutting speed. The worst surface finish with maximum of 28.17% difference under dry machining condition was observed. It was clearly seen that the blend of canola oil mixed with MoS2 particles improved the cooling and friction at the cutting zone. In addition, analysis on the scanning electron microscope (SEM) has been done on the worn tools for better comprehension of tool wear during turning of Inconel 718 alloy. Finally, it has been reported that the performance of the textured tool under solid lubrication conditions is better to achieve a lower tool wear (Vb), surface roughness (Ra), cutting forces, and acceptable form of chips.


Dry turning Inconel 718 alloy MQL Solid lubricant Surface roughness Textured tool Tool wear 



  1. 1.
  2. 2.
    Gupta M, Pruncu C, Mia M, Singh G, Singh S, Prakash C, Sood P, Gill H (2018) Machinability investigations of Inconel-800 super alloy under sustainable cooling conditions. Materials 11(11). CrossRefGoogle Scholar
  3. 3.
    Pollock TM, Tin S (2006) Nickel-based superalloys for advanced turbine engines: chemistry, microstructure and properties. J Propuls Power 22(2):361–374CrossRefGoogle Scholar
  4. 4.
    Jamil M, Khan AM, Hegab H, Gong L, Mia M, Gupta MK, He N (2019) Effects of hybrid Al2O3-CNT nanofluids and cryogenic cooling on machining of Ti–6Al–4V. Int J Adv Manuf Technol 102(9):3895–3909. CrossRefGoogle Scholar
  5. 5.
    Gupta MK, Mia M, Pruncu CI, Kapłonek W, Nadolny K, Patra K, Mikolajczyk T, Pimenov DY, Sarikaya M, Sharma VS (2019) Parametric optimization and process capability analysis for machining of nickel-based superalloy. Int J Adv Manuf Technol 102(9):3995–4009. CrossRefGoogle Scholar
  6. 6.
    Ezugwu E, Wang Z, Machado A (1999) The machinability of nickel-based alloys: a review. J Mater Process Technol 86(1–3):1–16CrossRefGoogle Scholar
  7. 7.
    Thakur A, Gangopadhyay S (2016) State-of-the-art in surface integrity in machining of nickel-based super alloys. Int J Mach Tools Manuf 100:25–54CrossRefGoogle Scholar
  8. 8.
    Zhu D, Zhang X, Ding H (2013) Tool wear characteristics in machining of nickel-based superalloys. Int J Mach Tools Manuf 64:60–77CrossRefGoogle Scholar
  9. 9.
    Krolczyk GM, Maruda RW, Krolczyk JB, Wojciechowski S, Mia M, Nieslony P, Budzik G (2019) Ecological trends in machining as a key factor in sustainable production—a review. J Clean Prod 218:601–615. CrossRefGoogle Scholar
  10. 10.
    Yazid M, CheHaron C, Ghani J, Ibrahim G, Said A (2011) Surface integrity of Inconel 718 when finish turning with PVD coated carbide tool under MQL. Procedia Engineering 19:396–401CrossRefGoogle Scholar
  11. 11.
    Zhang S, Li JF, Wang YW (2012) Tool life and cutting forces in end milling Inconel 718 under dry and minimum quantity cooling lubrication cutting conditions. J Clean Prod 32:81–87. CrossRefGoogle Scholar
  12. 12.
    Tebaldo V, di Confiengo GG, Faga MG (2017) Sustainability in machining: “eco-friendly” turning of Inconel 718. Surface characterisation and economic analysis. J Clean Prod 140:1567–1577CrossRefGoogle Scholar
  13. 13.
    Dureja J, Singh R, Singh T, Singh P, Dogra M, Bhatti MS (2015) Performance evaluation of coated carbide tool in machining of stainless steel (AISI 202) under minimum quantity lubrication (MQL). Int J Precis Eng Manuf Green Technol 2(2):123–129CrossRefGoogle Scholar
  14. 14.
    Sugihara T, Enomoto T (2009) Development of a cutting tool with a textured surface for dry cutting of aluminum alloys. Int J Autom Technol 3(2):199–203CrossRefGoogle Scholar
  15. 15.
    Darshan C, Jain S, Dogra M, Gupta MK, Mia M (2019) Machinability improvement in Inconel-718 by enhanced tribological and thermal environment using textured tool. J Therm Anal Calorim. CrossRefGoogle Scholar
  16. 16.
    Kawasegi N, Sugimori H, Morimoto H, Morita N, Hori I (2009) Development of cutting tools with microscale and nanoscale textures to improve frictional behavior. Precis Eng 33(3):248–254CrossRefGoogle Scholar
  17. 17.
    Arulkirubakaran D, Senthilkumar V, Kumawat V (2016) Effect of micro-textured tools on machining of Ti–6Al–4V alloy: an experimental and numerical approach. Int J Refract Met Hard Mater 54:165–177CrossRefGoogle Scholar
  18. 18.
    Koshy P, Tovey J (2011) Performance of electrical discharge textured cutting tools. CIRP Ann 60(1):153–156CrossRefGoogle Scholar
  19. 19.
    Behera B, Ghosh S, Rao P (2016) Application of nanofluids during minimum quantity lubrication: a case study in turning process. Tribol Int 101:234–246CrossRefGoogle Scholar
  20. 20.
    Ghosh S, Rao PV (2015) Application of sustainable techniques in metal cutting for enhanced machinability: a review. J Clean Prod 100:17–34CrossRefGoogle Scholar
  21. 21.
    Sharma AK, Singh RK, Dixit AR, Tiwari AK (2016) Characterization and experimental investigation of Al2O3 nanoparticle based cutting fluid in turning of AISI 1040 steel under minimum quantity lubrication (MQL). Mater Today: Proc 3(6):1899–1906Google Scholar
  22. 22.
    Sidik NAC, Samion S, Ghaderian J, Yazid MNAWM (2017) Recent progress on the application of nanofluids in minimum quantity lubrication machining: a review. Int J Heat Mass Transf 108:79–89CrossRefGoogle Scholar
  23. 23.
    Sen B, Hussain SAI, Mia M, Mandal UK, Mondal SP (2019) Selection of an ideal MQL-assisted milling condition: an NSGA-II-coupled TOPSIS approach for improving machinability of Inconel 690. Int J Adv Manuf Technol 103:1811–1829. CrossRefGoogle Scholar
  24. 24.
    Singh G, Gupta MK, Mia M, Sharma VS (2018) Modeling and optimization of tool wear in MQL-assisted milling of Inconel 718 superalloy using evolutionary techniques. Int J Adv Manuf Technol 97(1):481–494. CrossRefGoogle Scholar
  25. 25.
    Khan MA, Mia M, Dhar NR (2017) High-pressure coolant on flank and rake surfaces of tool in turning of Ti-6Al-4V: investigations on forces, temperature, and chips. Int J Adv Manuf Technol 90(5):1977–1991. CrossRefGoogle Scholar
  26. 26.
    Mia M, Dhar NR (2018) Effects of duplex jets high-pressure coolant on machining temperature and machinability of Ti-6Al-4V superalloy. J Mater Process Technol 252:688–696. CrossRefGoogle Scholar
  27. 27.
    Mia M, Khan MA, Dhar NR (2017) High-pressure coolant on flank and rake surfaces of tool in turning of Ti-6Al-4V: investigations on surface roughness and tool wear. Int J Adv Manuf Technol 90(5):1825–1834. CrossRefGoogle Scholar
  28. 28.
    Hegab H, Umer U, Soliman M, Kishawy HA (2018) Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718. Int J Adv Manuf Technol 96(9–12):3449–3458CrossRefGoogle Scholar
  29. 29.
    Sartori S, Ghiotti A, Bruschi S (2018) Solid lubricant-assisted minimum quantity lubrication and cooling strategies to improve Ti6Al4V machinability in finishing turning. Tribol Int 118:287–294CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Chetan Darshan
    • 1
  • Sumit Jain
    • 2
  • Manu Dogra
    • 3
  • Munish Kumar Gupta
    • 4
  • Mozammel Mia
    • 5
    Email author
  • Raisul Haque
    • 5
  1. 1.I.K.Gujral Punjab Technical UniversityJalandharIndia
  2. 2.Mechanical Engineering DepartmentCT Institute of Engineering Management &TechnologyJalandharIndia
  3. 3.Mechanical Engineering Department, SSG Regional CenterUIET Panjab UniversityHoshiarpurIndia
  4. 4.Key Laboratory of High Efficiency and Clean Mechanical Manufacture, School of Mechanical EngineeringShandong UniversityJinanChina
  5. 5.Mechanical and Production EngineeringAhsanullah University of Science and TechnologyDhakaBangladesh

Personalised recommendations