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Towards green machining: wear analysis of a novel eco-friendly cooling strategy for Inconel 718

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Abstract

Inconel 718, valued for its remarkable mechanical, corrosion, and high-temperature resistance up to 700 °C, is a predominant material constituting almost half of all global superalloy usage. Nonetheless, its exceptional properties make it a challenging material to machine, generating elevated heat at the tool-chip interface that strains cutting tools. Although ceramic tools offer one avenue, cemented carbide tools, particularly in “S” grades, find utilization despite limitations. To render cemented carbide tools viable, a lubricating-cooling medium is essential. Traditionally, abundant cutting fluids or conventional flood application (CFA) are employed. Nevertheless, CFA’s broad use raises sustainability concerns across economic, social, and environmental spheres. To address this, extensive global research aims to explore alternatives or substitutes for CFA. This study introduces an innovative approach using internally cooled tools (ICTs), which eliminates fluid release into the atmosphere, curbing improper disposal. ICT operates within a closed-loop cycle, cooling the tool. Moreover, ICT offers low toxicity for operators, minimizing direct contact risks and workplace contamination. Employing cemented carbide inserts with internal coolant galleries, the ICT method underwent tool life tests during Inconel 718 turning, followed by wear mechanism analyses. The study involved three cutting atmospheres (ICT, CFA, and dry machining (DM)) and two tool coating variations (TiNAl and a double coating AlCrN + TiNAl, referred as AlCrN+). With consistent finishing conditions, cutting speed (vc = 45 m/min), feed rate (f = 0.103 mm/rev), and depth of cut (ap = 0.5 mm) remained unchanged. Replicated twice for statistical validity, 18 experiments were conducted. After testing, scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS) unveiled wear mechanisms. Results indicated  AlCrN+ surpassed TiAlN coatings, 35% better on average. In contrast, ICT delivered optimal TiAlN-coated tool life, even better than CFA, 27% better. Conversely, AlCrN + coatings achieved the best outcomes with CFA. Irrespective of tool coating or atmosphere, observed wear mechanisms encompassed abrasion, adhesion, and diffusion, with AlCrN+ exhibiting smoother, more uniform wear, predominantly flank, and crater wear. Finally, ICT has shown to be a promising eco-friendly technique with high industrial potential to be explored and improved.

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Data availability

The datasets obtained during the current work are available from the corresponding author upon request.

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Acknowledgements

The authors extend their gratitude to the following entities: The Grupo de Manufatura Sustentável—GMS (Group of Sustainable Manufacturing (GMS)) at the Laboratório de Ensino e Pesquisa em Usinagem—LEPU, Federal University of Uberlandia—Brazil, as well as Nipo-Tec—Special Tools, Walter Tools, Villares Metals SA, Ceratizit, Mapal Brasil, Oerlikon Balzers, Petronas, Fuchs, and Stellantis Latam. This work received support from Brazilian research agencies, including Coordenação de Aperfeiçoamento de Pessoal de Nível Superior—Brasil (CAPES) (grant number 001, 2019), Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) (grant number 001,2019), and Fundação de Amparo à Pesquisa do Estado de Minas Gerais—FAPEMIG (grant number 001,2019).

Funding

This study was funded by Tupy S.A. for providing the work material, Walter Tools for donating the tools, Nipo-Tec Ferramentas Industriais for designing and machining the channels of the ICT inserts by REDM, and Brazilian research agencies CNPq, FAPEMIG and Coordenação de Aperfeiçoamento de Pessoal de Nível Superior—Brasil (CAPES)—Finance Code 001 for the financial support.

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Authors and Affiliations

  1. Federal University of Uberlandia, Av. João Naves de Ávila, Uberlândia, MG, CEP, 212138400-902, Brazil

    Gustavo Henrique Nazareno Fernandes, Lucas Melo Queiroz Barbosa, Pedro Henrique Pires França & Álisson Rocha Machado

  2. University of South Australia, UniSA STEM, Mawson Lakes Campus, Mawson Lakes, SA, 5095, Australia

    Gustavo Henrique Nazareno Fernandes

  3. Stellantis Latam, Manufacturing Engineering, Betim, MG, Brazil

    Paulo Sérgio Martins

  4. Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná–PUCPR, Rua Imaculada Conceição, Curitiba, Paraná, 80215-901, Brazil

    Álisson Rocha Machado

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Contributions

Gustavo Henrique Nazareno Fernandes: conceptualization, methodology, validation, formal analysis, investigation, writing—original draft, visualization, project administration.

Lucas Melo Queiroz Barbosa: validation, investigation, data curation, writing— review and editing.

Pedro Henrique Pires França: validation, investigation, data curation.

Paulo S. Martins: funding acquisition, supervision, writing—review and editing, project administration.

Álisson R. Machado: writing—review and editing, supervision, project administration.

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Correspondence to Gustavo Henrique Nazareno Fernandes.

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Fernandes, G.H.N., Barbosa, L.M.Q., França, P.H.P. et al. Towards green machining: wear analysis of a novel eco-friendly cooling strategy for Inconel 718. Int J Adv Manuf Technol 129, 107–126 (2023). https://doi.org/10.1007/s00170-023-12207-1

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