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Effect of cryogenic coolant on machinability of difficult-to-machine Ni–Cr alloy using PVD-TiAlN coated WC tool

  • K. Nimel Sworna RossEmail author
  • G. Manimaran
Technical Paper
  • 74 Downloads

Abstract

Alloys of nickel are optimal metals to use in turbine parts and aircraft components. They are generally accepted as difficult-to-machine materials, because of its poor thermal conductivity. The selection of coolant and machining conditions is crucial for better performance. Problems with conventional coolant are failure of lubrication at higher metal removal and cause environmental pollution. The heat produced at the cutting zone can shorten the life of the tool, which leads to dimensional imprecision. The current experimental investigation is machining of Nimonic 80A under the effect of cryogenic liquid carbon dioxide (− 79.5 °C) using PVD-TiAlN coated tungsten carbide (WC) insert, which is compared with conventional dry, flood, and MQL environments. The machining is carried at varying cutting speed ranging from 45 to 90 m/min, a feed rate of 0.06–0.08 mm/tooth, and a constant depth of cut of 0.75 mm. The results admitted that cryogenic cooling lessens the average roughness by 42–47% over dry cutting, 24–27% over wet cutting, and 16–21% over MQL. It is proved that cryogenic cooling produces greater compressive stress on the machined surface and brings down the flank wear by decreasing the temperature on the cutting zone.

Graphical abstract

Keywords

Nimonic 80A Cryogenic carbon dioxide (LCO2MQL Soya bean oil PVD-TiAlN 

Abbreviations

MQL

Minimum quantity lubrication

LCO2

Liquid carbon dioxide

BUE

Build-up-edge

DOC

Depth of cut

PVD

Physical vapor deposition

Ra

Surface roughness

Vb

Flank wear

Vc

Cutting speed

fz

Feed rate

Notes

Acknowledgements

The authors express their gratitude to thank the Head of the Department and the staff members of the Mechanical Engineering Department, Saveetha Engineering College, Anna University, Chennai, for lending support during experimentation.

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Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringSaveetha Engineering CollegeChennaiIndia

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