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Enhancing sustainability in Inconel 718 machining: temperature control with internally cooled tools

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Abstract

Out of all the mechanical energy generated during material cutting, the majority is converted into heat, raising the temperature at the chip-tool interface, particularly in difficult-to-machine materials like Inconel 718, thereby diminishing tool lifespan. Consequently, various lubri-cooling methods mitigate issues related to high temperatures, such as reduced tool life and geometric distortions. The most employed method is cutting fluids application (CFA), but this approach poses several problems, including high cost and environmental and operator hazards. As a result, several techniques have been developed to lower machining temperatures, such as minimum quantity lubrication (MQL), cryogenics, and indirect tool cooling. In this study, an innovative method of tool cooling via internally cooled tool (ICT) was devised and tested. In this approach, the cooling fluid circulates in a closed loop without direct contact with the workpiece or even any fluid dispersion to the atmosphere, increasing environmental appeal and reducing manufacturing coasts. The developed method was compared with temperature measurements taken through thermography and a tool-workpiece thermocouple during the turning of Inconel 718. Two factorial designs studied temperature in Inconel 718 turning via thermocamera and tool-workpiece thermocouple. Additionally, the tool coating (TiNAl or AlCrN + TiNAl), cutting speed, feed, and depth of cut were varied. Using the tool-workpiece thermocouple method, ICT and CFA did not observe any statistically significant temperature difference. However, between ICT and DM, ICT exhibited a lower temperature at the tool-workpiece interface. With thermal imaging, ICT displayed a lower chip temperature than DM. In sum, internally cooled tools emerge as an innovative and environmentally sustainable solution for machining Inconel 718. They offer outstanding heat removal capabilities and substantial advantages over cutting fluids while significantly surpassing the performance of dry machining, thereby addressing crucial concerns in sustainable machining practices.

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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 would like to thank the following: The Grupo de Manufatura Sustentável (GMS) (Group of Manufacture Sustainable (GMS)) of the Laboratório de Ensino e Pesquisa em Usinagem (LEPU) at the Federal University of Uberlandia–Brazil; NipoTec–Special Tools; Walter Tools and Secco Tools; Villares Metals SA; Fiat Chrysler Automobiles (FCA). This work was supported by the Brazilian research agencies: Coordenação de Aperfeiçoamento de Pessoal de Nível Superior-Brasil (CAPES) (grant number 001, 2019), the 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. which provided the work material, Walter Tools donated the tools, Nipo-Tec Ferramentas Industriais designed and machined 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 financially supported.

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Authors and Affiliations

  1. Faculty of Mechanical Engineering, Federal University of Uberlândia - UFU, 2121, João Naves de Ávila avenue, Campus Santa Mônica, Uberlândia, MG, 38408-100, Brazil

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

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

    Gustavo Henrique Nazareno Fernandes

  3. Fiat Chrysler Automobiles - FCA, Manufacturing Engineering, Betim, MG, 32.669-900, Brazil

    Paulo Sérgio Martins

  4. Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná–PUCPR, Rua Imaculada Conceição, 1155, Prado Velho, Curitiba, PR, 80.215-901, 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.

Eduardo Ramos Ferreira: 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.

Notice: Some parts of this article were rewritten with the help of artificial intelligence to improve writing fluency.

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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. Enhancing sustainability in Inconel 718 machining: temperature control with internally cooled tools. Int J Adv Manuf Technol 131, 2771–2789 (2024). https://doi.org/10.1007/s00170-023-12296-y

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