Sustainable machining: an experimental investigation and optimization of machining Inconel 825 with dry and MQL approach

Abstract

Sustainability is a vital issue for present and future generation, and it aims to obtain overall efficiency in terms of economic, environmental and social aspects. Inconel 825 belongs to the family of nickel-based super alloy and is widely used in the chemical and marine industries. This work attempts to investigate machining performance of Inconel 825 using physical vapor deposition-titanium nitrate inserts, with a focus on sustainable machining. The effect of cutting parameters, viz. cutting speed (v), feed (f) and depth of cut (d) on three aspects of sustainability has been explored in two different machining environments, viz. dry and minimum quantity lubrication (MQL). The experimental results show a significant improvement in MQL machining and tool wear, and cutting power is reduced by 16.57 and 8.47%, respectively, and surface roughness is improved by 10.41%. The interacting effects of parameters on responses are studied using 3-D surface plots; it shows cutting speed and feed are found as dominating parameters on all the three responses. The novelty of this work is to optimize the process for the sustainable production of components by optimizing the process parameters with multiple and conflicting objectives. The sustainable optimization using genetic algorithm provides surface roughness (R a) as 0.49 lm, tool flank wear (VB) as 110.68 lm and cutting power (P) as 5.44 kW with better convergent capability having 4% deviation. For the application of manufacturing industry, an optimization table is generated for selection of optimum process parameters for achieving desired surface roughness with minimum VB or minimum P.

Experimental investigation and modelling of MQL assisted turning process during machining of 15-5 PH stainless steel using response surface methodology

“…Further, observed a significant reduction in cutting force, tool wear and white layer depth in MQL over dry cutting respectively. Tamang et al [32] beneficial results were observed with MQL cutting condition due to good lubrication effect over dry condition while turning of Inconel 825 material. Subsequently, optimum process parameters were determined using a genetic algorithm to solve multi objective problem.…”

Experimental evaluation of energy consumption in machine tools: a case study for a two-spindle turning center

“…Furthermore, constant consumption can be the energy which is consumed even when no actual metal cutting process is running. Tamang et al [17] are even more specific dividing the energy consumption of MTs in three modes:…”

“…In this mode, the measurement of active power of each component is done separately. As defined in Tamang et al [17], the constant portion of power is related to components that ensure the functionality of the MT in an event of starting the machining process. In such case, the components active in this mode are: internal light, hydraulic unit, lubrication system for guideways, electric panel fan, spindle cooling system, spindle heat exchanger, CNC drives and servomotors, which remain electrically powered, even if none cutting load is applied.…”

“…At such mode, the real material removal is performed to measure the consumed energy. As described by Tamang et al [17], the mode metal cutting represents the energy consumed only for material removal and can be extracted, since one knows the amount spent on Mod MT in air-cutting. This energy consumption is variable and depends on the load applied to the MT.…”

“…According to references [9][10][11][12][13][14], there are several strategies and technologies to be adopted in manufacturing toward reducing energy consumption. Topics such as sustainability and reduction in energy consumption are becoming extremely important in product development, besides classical decision-making attributes like cost, quality and flexibility [15][16][17]. As one of the major components in manufacturing industry, machine tools (MTs) are widely used in various transformation processes, adding value to the final product through material removal process with cutting tools.…”