–
Milling of nickel-based superalloys using throttle cryogenic cooling and micro-lubrication
IQBAL Asif, SAELZER Jannis, NAUMAN Malik M., BIERMANN Dirk
download PDFAbstract. Nickel-based alloys are known to mount intense heat around the cutting edges of the cutting tool owing to their high yield strength, comparatively low thermal conductivity, and a significant seizure of the chip at the rake face even at low cutting speeds. Their sustainable machining demands a highly effective heat dissipation system. Due to its rich cooling potential, the compressed CO2-based throttle cryogenic cooling system is a prime contender. The presented work seeks a sustainable milling solution for the cutting of the following three nickel-rich allows using the combination of throttle cryogenic cooling and minimum quantity of lubrication: Inconel 718, Incoloy 825, and Waspaloy. The experimental study quantifies the effects of the lubri-cooling approach and cutting speed on tool wear, cutting forces, and workpiece surface roughness. The novelty of the work lies in the mutual comparison of the machinability of the three alloys of nickel and the application of the cryogenic coolant in the form of pulses in addition to the conventional mode of continuous stream. The analyses of the experimental results suggest that the pulsed mode of the coolant, especially in combination with the lubricant, outperforms the continuous mode of the coolant’s supply regarding cutting forces and work surface roughness. Additionally, the study has yielded mixed results regarding tool wear for different combinations of workpiece material and cutting speed. Nonetheless, dry milling of the three alloys proved to be absolutely unsustainable in comparison to either of the two modes of throttle cryogenic cooling, with or without the application of micro-lubrication.
Keywords
Carbon Dioxide, Side-Milling, Tool Wear, Micro-Lubrication, Super-Alloys
Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: IQBAL Asif, SAELZER Jannis, NAUMAN Malik M., BIERMANN Dirk, Milling of nickel-based superalloys using throttle cryogenic cooling and micro-lubrication, Materials Research Proceedings, Vol. 41, pp 2093-2102, 2024
DOI: https://doi.org/10.21741/9781644903131-231
The article was published as article 231 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] D. Zhu, X. Zhang, H. Ding, Tool wear characteristics in machining of nickel-based superalloys. Int J Mach. Tools Manuf. 64 (2013), 60-77.
[2] https://doi.org/10.1016/j.ijmachtools.2012.08.001
[3] M. Anderson, R. Patwa, Y.C. Shin, Laser-assisted machining of Inconel 718 with an economic analysis. Int J Mach. Tools Manuf. 46 (2006)1879–1891. https://doi.org/10.1016/j.ijmachtools.2005.11.005
[4] M. Günay, M.E. Korkmaz, N. Yaşar, Performance analysis of coated carbide tool in turning of Nimonic 80A superalloy under different cutting environments. J Manuf. Process. 56 (2020) 678–687. https://doi.org/10.1016/j.jmapro.2020.05.031
[5] S. Rinaldi, S. Caruso, D. Umbrello, L. Filice, R. Franchi, A. Del Prete, Machinability of Waspaloy under different cutting and lubri-cooling conditions. Int. J Adv. Manuf. Technol.; 94 (2018), 3703–3712. https://doi.org/10.1007/s00170-017-1133-0
[6] A. Shokrani, S.T. Newman, Hybrid cooling and lubricating technology for CNC milling of Inconel 718 nickel alloy. Proc. 8th CIRP Conf. High Performance Cutting (HPC 2018) 77 (2018), 215–218. https://doi.org/10.1016/j.procir.2018.08.291
[7] M. Danish, M.K. Gupta, S. Rubaiee, A. Ahmed, M.E. Korkmaz, Influence of hybrid Cryo-MQL lubri-cooling strategy on the machining and tribological characteristics of Inconel 718. Tribol. Int. 163 (2021), 107178. https://doi.org/10.1016/j.triboint.2021.107178
[8] A. Bagherzadeh, B. Koc, E. Budak, M. Isik, High-speed machining of additively manufactured Inconel 718 using hybrid cryogenic cooling methods. Virt. Phys. Prototyp 17 (2022), 419–436. https://doi.org/10.1080/17452759.2022.2034081
[9] K. Ross, G. Manimara, Machining investigation of Nimonic-80A superalloy under cryogenic CO2 as coolant using PVD-TiAlN/TiN coated tool at 45° nozzle angle. Arab J Sci. Eng. 45 (2020), 9267–9281. https://doi.org/10.1007/s13369-020-04728-8
[10] R. Polvorosa, A. Suarez, L.N. Lopez de Lacalle, I. Cerrillo, A. Wretland, F. Veiga, Tool wear on nickel alloys with different coolant pressures: Comparison of Alloy 718 and Waspaloy. J Manuf. Process. 26 (2017), 44–56. https://doi.org/10.1016/j.jmapro.2017.01.012
[11] X. Lu, Z. Jia, H. Wang, L. Si, Y. Liu, W. Wu, Tool wear appearance and failure mechanism of coated carbide tools in micro-milling of Inconel 718 super alloy. Indust. Lub. & Tribol. 68 (2016), 267–277. https://doi.org/10.1108/ILT-07-2015-0114
[12] F. Wang, Y. Wang, Comparison of cryogenic cooling strategy effects on machinability of milling nickel-based alloy. J Manuf. Proc. 66 (2021), 623-635. https://doi.org/10.1016/j.jmapro.2021.04.050
[13] S. Chaabani, I. Rodriguez, M. Cuesta, Y. Ayed, P. J. Arrazola, G. Germain. Tool wear and cutting forces when machining inconel 718 under cryogenic conditions: Liquid nitrogen and carbon dioxide. In AIP Conference Proceedings, vol. 2113, no. 1 (2019). AIP Publishing.
