Skip to main content
SpringerLink
Log in

Machinability of Inconel 825 under nano-Al2O3 based nanofluid minimum quantity lubrication

  • Published:
Sādhanā Aims and scope Submit manuscript

Abstract

In the present work, turning performance of Inconel 825 superalloy is studied under Nanofluid Minimum Quantity Lubrication (NFMQL). Nanofluid used is nano-Al2O3 dispersed distilled water. The tool insert used in this study is PVD multi-layered (TiN/ TiCN/ TiN) coated cermet. The following machining performance indicators: tangential cutting force, tool-tip temperature, wear morphologies of the tool insert, macro/ micro-morphologies of chips produced, etc. are studied. It is observed that dry machining environment causes vibration signals of random nature whose frequency and amplitude of acceleration are highly time-variant. On the contrary, periodic vibration signal with lower amplitude of acceleration is detected in case of NFMQL machining. Consequently, NFMQL exhibits lower cutting force, reduced tool-tip temperature, and less severe tool wear than that of dry machining. NFMQL produces thinner chips with shorter segmentation spacing and wider shear angle than dry machining.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13

Similar content being viewed by others

References

  1. Ezugwu E O and Okeke C I 2000 Performance of PVD coated carbide inserts when machining a nimonic (C-263) alloy at high speed conditions. Tribol. Trans. 43(2): 332–336

    Article  Google Scholar 

  2. Kuo C P, Su S C and Chen S H 2010 Tool life and surface integrity when milling Inconel 718 with coated cemented carbide tools. J. Chin. Inst. Eng. 33(6): 915–922

    Article  Google Scholar 

  3. Nalbant M, Altın A and Gökkaya H 2007 The effect of coating material and geometry of cutting tool and cutting speed on machinability properties of Inconel 718 super alloys. Mater. Des. 28(5): 1719–1724

    Article  Google Scholar 

  4. Kadirgama K, Abou-El-Hossein K A, Noor M M, Sharma K V and Mohammad B 2011 Tool life and wear mechanism when machining Hastelloy C-22HS. Wear 270(3–4): 258–268

    Article  Google Scholar 

  5. Liew P J, Shaaroni A, Sidik N A C and Yan J 2017 An overview of current status of cutting fluids and cooling techniques of turning hard steel. Int. J. Heat Mass Transf. 114: 380–394

    Article  Google Scholar 

  6. Bennett E O 1983 Water based cutting fluids and human health. Tribol. Int. 16(3): 133–136

    Article  Google Scholar 

  7. Debnath S, Reddy M M and Yi Q S 2014 Environmental friendly cutting fluids and cooling techniques in machining: a review. J. Clean. Prod. 83: 33–47

    Article  Google Scholar 

  8. Li K M and Liang S Y 2007 Performance profiling of minimum quantity lubrication in machining. Int. J. Adv. Manuf. Technol. 35(3): 226–233

    Article  MathSciNet  Google Scholar 

  9. Yazid M Z A, CheHaron C H, Ghani J A, Ibrahim G A and Said A Y M 2011 Surface integrity of Inconel 718 when finish turning with PVD coated carbide tool under MQL. Procedia Eng. 19: 396–401

    Article  Google Scholar 

  10. Yıldırım Ç V, Kıvak T, Sarıkaya M and Erzincanlı F 2017 Determination of MQL parameters contributing to sustainable machining in the milling of nickel-base superalloy Waspaloy. Arab. J. Sci. Eng. 42(11): 4667–4681

    Article  Google Scholar 

  11. Wang C, Li K, Chen M and Liu Z 2015 Evaluation of minimum quantity lubrication effects by cutting force signals in face milling of Inconel 182 overlays. J. Clean. Prod. 108: 145–157

    Article  Google Scholar 

  12. Kamata Y and Obikawa T 2007 High speed MQL finish-turning of Inconel 718 with different coated tools. J. Mater. Process. Technol. 192: 281–286

    Article  Google Scholar 

  13. Tawakoli T, Hadad M J, Sadeghi M H, Daneshi A, Stöckert S and Rasifard A 2009 An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication—MQL grinding. Int. J. Mach. Tools Manuf. 49(12–13): 924–932

    Article  Google Scholar 

  14. Vasu V and Reddy G P K 2011 Effect of minimum quantity lubrication with Al2O3 nanoparticles on surface roughness, tool wear and temperature dissipation in machining Inconel 600 alloy. Proc. IMechE, Part N: Journal of Nanomater. Nanoeng. Nanosyst. 225(1): 3–16

  15. Khandekar S, Sankar M R, Agnihotri V and Ramkumar J 2012 Nano-cutting fluid for enhancement of metal cutting performance. Mater. Manuf. Process. 27(9): 963–967

    Article  Google Scholar 

  16. Amrita M, Srikant R R and Sitaramaraju A V 2014 Performance evaluation of nanographite-based cutting fluid in machining process. Mater. Manuf. Process. 29(5): 600–605

    Article  Google Scholar 

  17. Padmini R, Krishna P V and Rao G K M 2015 Performance assessment of micro and nano solid lubricant suspensions in vegetable oils during machining. Proc. IMechE, Part B: J. Eng. Manuf. 229(12): 2196–2204

  18. Paturi U M R, Maddu Y R, Maruri R R and Narala S K R 2016 Measurement and analysis of surface roughness in WS2 solid lubricant assisted minimum quantity lubrication (MQL) turning of Inconel 718. Procedia CIRP. 40: 138–143

    Article  Google Scholar 

  19. Ali M A M, Khalil A N M and Azmi A I 2016 Effect of Al2O3 nanolubrication with Sodium Dodecylbenzene Sulfonate (SDBS) on surface roughness and tool wear under MQL during turning of Ti-6AL-4T. IOP Conf. Ser.: Mater. Sci. Eng. 114(1): 012110 DOI: https://doi.org/10.1088/1757-899X/114/1/012110

  20. Behera B C, Chetan, Setti D, Ghosh S and Rao P V 2017 Spreadability studies of metal working fluids on tool surface and its impact on minimum amount cooling and lubrication turning. J. Mater. Process. Technol. 244: 1–16

    Article  Google Scholar 

  21. Singh R K, Sharma A K, Dixit A R, Tiwari A K, Pramanik A and Mandal A 2017 Performance evaluation of alumina-graphene hybrid nano-cutting fluid in hard turning. J. Clean. Prod. 162: 830–845

    Article  Google Scholar 

  22. Sinha M K, Madarkar R, Ghosh S and Rao P V 2017 Application of eco-friendly nanofluids during grinding of Inconel 718 through small quantity lubrication. J. Clean. Prod. 141: 1359–1375

    Article  Google Scholar 

  23. Virdi R L, Chatha S S and Singh H 2019 Experiment evaluation of grinding properties under Al2O3 nanofluids in minimum quantity lubrication. Mater. Res. Express. 6(9): 096574. https://doi.org/10.1088/2053-1591/ab301f

    Article  Google Scholar 

  24. Sen B, Mia M, Gupta M K, Rahman M A, Mandal U K and Mondal S P 2019 Influence of Al2O3 and palm oil–mixed nanofluid on machining performances of Inconel-690: IF-THEN rules–based FIS model in eco-benign milling. Int. J. Adv. Manuf. Technol. 103(9): 3389–3403

    Article  Google Scholar 

  25. Duc T M, Long T T and Thanh D V 2020 Evaluation of minimum quantity lubrication and minimum quantity cooling lubrication performance in hard drilling of Hardox 500 steel using Al2O3 nanofluid. Adv. Mech. Eng. 12(2): 1687814019888404. https://doi.org/10.1177/1687814019888404

    Article  Google Scholar 

  26. Wang Y, Li C, Zhang Y, Yang M, Zhang X, Zhang N and Dai J 2017 Experimental evaluation on tribological performance of the wheel/workpiece interface in minimum quantity lubrication grinding with different concentrations of Al2O3 nanofluids. J. Clean. Prod. 142: 3571–3583

    Article  Google Scholar 

  27. Liljerehn A 2016 Machine tool dynamics, a constrained state-space substructuring approach, PhD Thesis, Department of Applied Mechanics, Chalmers University of Technology, Göteborg, Sweden (2016)

  28. Byrne G, Dornfeld D, Inasaki I, Ketteler G, König W and Teti R 1995 Tool condition monitoring (TCM) – the status of research and industrial application. Ann. CIRP. 44(2): 541–567

    Article  Google Scholar 

  29. Dimla Snr D E 2000 Sensor signals for tool wear monitoring in metal cutting operations – a review of methods. Int. J. Mach. Tools Manuf. 40(8): 1073–1098

    Article  Google Scholar 

  30. Dimla Snr D E 2002 The correlation of vibration signal features to cutting tool wear in a metal turning operation. Int. J. Adv. Manuf. Technol. 19: 705–713

    Article  Google Scholar 

  31. David A S and John S A 2006 Metal cutting theory and practice. Taylor and Francis 1st edition, 45–69

  32. Carou D, Rubio E M, Lauro C H and Davim J P 2016 The effect of minimum quantity lubrication in the intermittent turning of magnesium based on vibration signals. Measurement. 94: 338–343

    Article  Google Scholar 

  33. Lengauer W and Scagnetto F 2018 Ti (C, N)-based cermets: critical review of achievements and recent developments. Solid State Phenom. 274: 53–100

    Article  Google Scholar 

  34. Sulaiman S, Roshan A and Borazjani S 2013 Effect of cutting parameters on cutting temperature of TiAl6V4 alloy. Appl. Mech. Mater. 392: 68–72

    Article  Google Scholar 

  35. Noordin M Y, Venkatesh V C and Sharif S 2007 Dry turning of tempered martensitic stainless tool steel using coated cermet and coated carbide tools. J. Mater. Process. Technol. 185(1–3): 83–90

    Article  Google Scholar 

  36. Reis B C M, dos Santos A J, dos Santos N F P, Câmara M A, de Faria P E and Abrão A M 2019 Cutting performance and wear behavior of coated cermet and coated carbide tools when turning AISI 4340 steel. Int. J. Adv. Manuf. Technol. 105(1): 1655–1663

    Article  Google Scholar 

  37. Babu M N, Anandan V and Babu M D 2021 Performance of ionic liquid as a lubricant in turning inconel 825 via minimum quantity lubrication method. J. Manuf. Process. 64: 793–804

    Article  Google Scholar 

  38. Marques A, Suarez M P, Sales W F and Machado Á R 2019 Turning of Inconel 718 with whisker-reinforced ceramic tools applying vegetable-based cutting fluid mixed with solid lubricants by MQL. J. Mater. Process. Technol. 266: 530–543

    Article  Google Scholar 

  39. Li H Z, Zeng H and Chen X Q 2006 An experimental study of tool wear and cutting force variation in the end milling of Inconel 718 with coated carbide inserts. J. Mater. Process. Technol. 180(1–3): 296–304

    Google Scholar 

  40. Luo T, Wei X, Huang X, Huang L and Yang F 2014 Tribological properties of Al2O3 nanoparticles as lubricating oil additives. Ceram. Int. 40(5): 7143–7149

    Article  Google Scholar 

  41. Pusavec F, Deshpande A, Yang S, M’Saoubi R, Kopac J, Dillon O W Jr and Jawahir I S 2014 Sustainable machining of high temperature Nickel alloy–Inconel 718: Part 1–predictive performance models. J. Clean. Prod. 81: 255–269

    Article  Google Scholar 

  42. Ahmed Y S, Fox-Rabinovich G, Paiva J M, Wagg T and Veldhuis S C 2017 Effect of built-up edge formation during stable state of wear in AISI 304 stainless steel on machining performance and surface integrity of the machined part. Mater. 10(11): 1230. https://doi.org/10.3390/ma10111230

    Article  Google Scholar 

  43. Hao Z, Gao D, Fan Y and Han R 2011 New observations on tool wear mechanism in dry machining Inconel 718. Int. J. Mach. Tools Manuf. 51(12): 973–979

    Article  Google Scholar 

  44. Khanna N, Shah P and Chetan, 2020 Comparative analysis of dry, flood, MQL and cryogenic CO2 techniques during the machining of 15–5-PH SS alloy. Tribol. Int. 146: 106196. https://doi.org/10.1016/j.triboint.2020.106196

    Article  Google Scholar 

  45. Ghani J A, Haron C H C, Kasim M S, Sulaiman M A and Tomadi S H 2016 Wear mechanism of coated and uncoated carbide cutting tool in machining process. J. Mater. Res. 31(13): 1873–1879

    Article  Google Scholar 

  46. Günan F, Kıvak T, Yıldırım Ç V and Sarıkaya M 2020 Performance evaluation of MQL with Al2O3 mixed nanofluids prepared at different concentrations in milling of Hastelloy C276 alloy. J. Mater. Res. Technol. 9(5): 10386–10400

    Article  Google Scholar 

  47. Chetan Ghosh S and Rao P V 2019 Comparison between sustainable cryogenic techniques and nano-MQL cooling mode in turning of nickel-based alloy. J. Clean. Prod. 231: 1036–1049

    Article  Google Scholar 

  48. Zhang S, Li J, Zhu X and Lv H 2013 Saw-tooth chip formation and its effect on cutting force fluctuation in turning of Inconel 718. Int. J. Precis. Eng. Manuf. 14(6): 957–963

    Article  Google Scholar 

  49. Das S R, Dhupal D and Kumar A 2015 Experimental investigation into machinability of hardened AISI 4140 steel using TiN coated ceramic tool. Measurement. 62: 108–126

    Article  Google Scholar 

  50. Hegab H, Umer U, Soliman M and Kishawy H A 2018 Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718. Int. J. Adv. Manuf. Technol. 96(9): 3449–3458

    Article  Google Scholar 

  51. Thakur D G, Ramamoorthy B and Vijayaraghavan L 2009 Machinability investigation of Inconel 718 in high-speed turning. Int. J. Adv. Manuf. Technol. 45(5–6): 421–429

    Article  Google Scholar 

  52. Dong G, Zhaopeng H, Rongdi H, Yanli C and Muguthu J N 2011 Study of cutting deformation in machining nickel-based alloy Inconel 718. Int. J. Mach. Tools Manuf. 51(6): 520–527

    Article  Google Scholar 

  53. Ning F, Wang F, Jia Z and Ma J 2014 Chip morphology and surface roughness in high-speed milling of nickel-based superalloy Inconel 718. Int. J. Mach. Mach. Mater. 15(3–4): 285–299

    Google Scholar 

  54. Kaynak Y 2014 Evaluation of machining performance in cryogenic machining of Inconel 718 and comparison with dry and MQL machining. Int. J. Adv. Manuf. Technol. 72(5): 919–933

    Article  Google Scholar 

  55. Subramanian S V, Gekonde H O, Zhu G and Zhang X 2002 Role of microstructural softening events in metal cutting. Mach. Sci. Technol.: Int. J. 6(3): 353–364

  56. Oxley P L B 1998 Development and application of a predictive machining theory. Mach. Sci. Technol.: Int. J. 2(2): 165–189

  57. Sayuti M, Sarhan A A, Tanaka T, Hamdi M and Saito Y 2013 Cutting force reduction and surface quality improvement in machining of aerospace duralumin Al-2017-T4 using carbon onion nanolubrication system. Int. J. Adv. Manuf. Technol. 65(9–12): 1493–1500

    Article  Google Scholar 

  58. Peng D X, Kang Y, Hwang R M, Shyr S S and Chang Y P 2009 Tribological properties of diamond and SiO2 nanoparticles added in paraffin. Tribol. Int. 42(6): 911–917

    Article  Google Scholar 

  59. Dash L, Padhan S and Das S R 2020 Experimental investigations on surface integrity and chip morphology in hard tuning of AISI D3 steel under sustainable nanofluid-based minimum quantity lubrication. J. Braz. Soc. Mech. Sci. Eng. 42(10): 1–25

    Article  Google Scholar 

  60. Mia M, Dey P R, Hossain M S, Arafat M T, Asaduzzaman M, Ullah M S and Zobaer S M T 2018 Taguchi S/N based optimization of machining parameters for surface roughness, tool wear and material removal rate in hard turning under MQL cutting condition. Measurement 122: 380–391

    Article  Google Scholar 

  61. Wang Q, Liu Z, Wang B, Song Q and Wan Y 2016 Evolutions of grain size and micro-hardness during chip formation and machined surface generation for Ti-6Al-4V in high-speed machining. Int. J. Adv. Manuf. Technol. 82(9–12): 1725–1736

    Article  Google Scholar 

  62. Joshi S, Tewari A and Joshi S S 2015 Microstructural characterization of chip segmentation under different machining environments in orthogonal machining of Ti6Al4V. J. Eng. Mater. Technol. 137(1): 011005 (16 pages) DOI: https://doi.org/10.1115/1.4028841

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology, Rourkela, Odisha, 769008, India

    Kshitij Pandey, Saurav Datta & Tarapada Roy

Authors
  1. Kshitij Pandey
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Saurav Datta
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Tarapada Roy
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Saurav Datta.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Pandey, K., Datta, S. & Roy, T. Machinability of Inconel 825 under nano-Al2O3 based nanofluid minimum quantity lubrication. Sādhanā 47, 127 (2022). https://doi.org/10.1007/s12046-022-01888-1

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s12046-022-01888-1

Keywords

Search

Navigation