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Towards green manufacturing: investigating tool coatings and cooling strategies for Inconel 718 turning

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Abstract

Machining Inconel 718, a high-strength superalloy with applications in critical industries, presents unique challenges. Conventional cutting fluid application has long been employed for machining Inconel 718 with cemented carbide tools. While it effectively provides cooling and lubrication, it raises significant sustainability concerns. It contributes substantially to production costs, poses environmental toxicity risks, and impacts workplace safety and environmental well-being. Researchers have explored alternative cooling strategies to mitigate these issues, including minimum quantity lubrication, cryogenic fluids, and minimum quantity cooled lubrication. However, even these less enviromental harmful machining cooling techniques have some fluid dispersion into the atmosphere, creating some sustainable impact. Thus, an ideal cooling system should adopt a closed-loop system to prevent fluid dispersion, ensuring eco-friendliness while offering efficient lubri-cooling for chip formation. This study introduces and evaluates the performance of an internally cooled tool system, utilizing cemented carbide square inserts with internal galleries for continuous water circulation within a closed loop. These new tools were rigorously tested in turning Inconel 718 superalloy and benchmarked against conventional cutting fluids and dry machining. The experimental factors encompassed these three different cutting atmospheres and tool coatings (TiNAl or AlCrN over TiNAl - AlCrN+). The key performance metrics assessed included cutting forces, workpiece surface roughness, and tool life. The primary conclusion revealed that the internally cooled tools outperformed cutting fluids when employing the TiNAl coating, exhibiting a material removal rate 27% higher than cutting fluids and an impressive 262% gain over dry machining. AlCrN+ with cutting fluids demonstrated the most exceptional performance, yielding a material removal rate 46% superior to internally cooled tools and an astonishing 306% increase compared to dry machining. The influence of TiNAl on increasing cutting forces was consistent with expectations, primarily due to its higher coefficient of friction relative to AlCrN+. The other input variables exhibited no statistically significant differences under the tested conditions. 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 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, Villares Metals SA, Ceratiziti, Mapal Brasil, Oerlikon Balzers, Petronas, Fuchs, Stellantis Latam. The Brazilian research agencies supported this work: 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. for providing the work material, Walter Tools from donating the tools, Nipo-Tec Ferramentas Industriais for designing and machining the channels of the ICTs 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, 2121, João Naves de Ávila Avenue, Uberlândia, MG, 38400-902, Brazil

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

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

    Gustavo Henrique Nazareno Fernandes

  3. Stellantis Latam, Manufacturing Engineering, 3455 Contorno st., Betim, MG, Brazil, 32669-900

    Paulo Sérgio Martins

  4. Pontifícia Universidade Católica do Paraná – PUCPR, 1155 Imaculada Conceição st., Curitiba, PR, 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 & editing.

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

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

Álisson R. Machado: Writing—Review & Editing, supervision, project administration.

Corresponding author

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 manufacturing: investigating tool coatings and cooling strategies for Inconel 718 turning. Int J Adv Manuf Technol 129, 2257–2279 (2023). https://doi.org/10.1007/s00170-023-12390-1

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