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Towards sustainability assessment, energy consumption, and carbon emissions in cryogenic drilling of Alloy 20: a new approach towards sustainable future and challenges

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Abstract

Both the product and the manufacturing process must be sustainable in today’s modern world. Traditional machining methods are undesirable when working with heat-resistant alloys. These methods could be more efficient and can be maintained over time. As the world progresses to sustainability, many people are working to integrate this concept into the industrial process. In the manufacturing industry, the evaluation of sustainability carries immense significance in ensuring product quality, promoting operators’ safety and well-being, and preventing any form of environmental degradation or pollution. Concerning this regard, the main objective of the present study is to assess the sustainability parameters during the drilling of Alloy 20 material under different environmental conditions such as minimum quantity lubrication (MQL) and cryogenic and hybrid methods. The study is conducted in two stages, and in the first stage, the most impactful sustainable indicators, i.e., energy consumption, carbon emissions, total cycle time, and cost, have been evaluated. In the second phase of the investigation, the machining analysis of surface roughness, cutting forces, and circularity was determined under different conditions. The results showed that the hybrid cooling condition exhibited better technical, quality, and economic sustainability. Thus, it is important to note that selecting appropriate cooling conditions can contribute to achieving sustainability in manufacturing processes and that the hybrid cooling method aids industries in moving towards sustainable production systems that, in turn, contribute to a more environmentally conscious and efficient economy.

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Funding

This work is supported by Future for Young Scholars of Shandong University, China (31360082064026, 31360082164007) and by Fundamental Research Funds of Shandong University (2019HW040).

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Authors and Affiliations

  1. Key Laboratory of High-Efficiency and Clean Mechanical Manufacture, National Demonstration Center for Experimental Mechanical Engineering Education, School of Mechanical Engineering, Shandong University, Jinan, 250061, Shandong, China

    Vinothkumar Sivalingam, Haochen Liu, Guo Kai & Jie Sun

  2. Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Saveetha University, Chennai, India

    Vinothkumar Sivalingam

  3. Department of Mechanical Engineering, Madanapalle Institute of Technology & Science, Madanapalle, Andhra Pradesh, 517325, India

    Baskaran Selvam

  4. Department of Mechanical Engineering, Faculty of Engineering and Technology, SRM Institute of Science and Technology, Kattankulathur, Tamil Nadu, India

    Poongavanam Ganesh Kumar

  5. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45‑758, Opole, Poland

    Munish Kumar Gupta

  6. Department of Mechanical Engineering, Graphic Era (Deemed to Be University), Dehradun, Uttarakhand, India

    Munish Kumar Gupta

  7. Department of Mechanical Engineering, Karabük University, Karabük, Turkey

    Mehmet Erdi Korkmaz

Authors
  1. Vinothkumar Sivalingam
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  2. Haochen Liu
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  3. Baskaran Selvam
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  4. Guo Kai
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  5. Poongavanam Ganesh Kumar
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  6. Munish Kumar Gupta
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  7. Mehmet Erdi Korkmaz
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  8. Jie Sun
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Correspondence to Vinothkumar Sivalingam or Munish Kumar Gupta.

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Sivalingam, V., Liu, H., Selvam, B. et al. Towards sustainability assessment, energy consumption, and carbon emissions in cryogenic drilling of Alloy 20: a new approach towards sustainable future and challenges. Int J Adv Manuf Technol 131, 1151–1165 (2024). https://doi.org/10.1007/s00170-024-13144-3

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