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Machinability analysis of nickel-based superalloy Nimonic 90: a comparison between wet and LCO2 as a cryogenic coolant

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Abstract

The usage of cryogenic fluid is increasing in the machining industries especially to cut the materials having a lower machinability like Nimonic 90, a nickel-based alloy. However, the comparison of flood coolant and LCO2 as a cryogenic fluid based on machining performance has not been found for machining Nimonic 90. In this regard, this study compares LCO2 and conventional mineral oil-based flood coolant on the basis of machining performance while turning Nimonic 90. The effect of turning process parameters (cutting speed (vc), feed (f), and depth of cut (ap)) and cutting fluids has been identified by analyzing machinability indicators like cutting force, flank tool wear, power consumption, surface roughness in terms of Ra, and chip morphology. Increment of 34%, 25%, and 24% in cutting forces has been observed for cryogenic turning using LCO2 in comparison with wet machining when the values of ap are 0.75, 0.50, and 0.25 mm, respectively. A decrement of 63% tool wear has been seen in LCO2 cryogenic fluid in contrast to wet machining at higher values of vc, f, and ap. The superior surface finish has been found in wet machining, while lesser power consumption was recorded for LCO2 as a cutting fluid. Cryogenic machining provided better chip breakability in comparison with wet machining.

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Abbreviations

v c :

Cutting speed (m/min)

f :

Longitudinal feed (mm/rev)

a p :

Axial depth of cut (mm)

CRC :

Chip reduction coefficient

R a :

Arithmetic mean for the absolute values of roughness profile (μm)

LCO2 :

Liquid carbon dioxide

LN2 :

Liquid nitrogen

MQL:

Minimum quantity lubrication

CryoMQL:

Hybrid cutting conditions (cryogenic fluid and MQL)

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Funding

The authors would like to thank the SERB-DST, Government of India, for the financial support given under the Project (ECR/2016/000735), titled “Design and Development of Energy Efficient Cryogenic Machining Facility for Heat Resistant Alloys and Carbon Fibre Composites.”

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Authors and Affiliations

  1. Advanced Manufacturing Laboratory, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmedabad, 380026, India

    Tej Patel, Navneet Khanna, Sahitya Yadav & Prassan Shah

  2. Department of Mechanical Engineering, Sinop University, 57030, Sinop, Turkey

    Murat Sarikaya

  3. CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, 713209, India

    Dilpreet Singh

  4. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, School of Mechanical Engineering, Shandong University, **an, People’s Republic of China

    Munish Kumar Gupta

  5. Mechanical Engineering Department, BITS-Pilani, Hyderabad Campus, Hyderabad, Telangana, 500078, India

    Nitin Kotkunde

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  1. Tej Patel
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Contributions

Conceptualization: T. Patel, N. Khanna, S. Yadav, P. Shah, and M. Sarikaya. Methodology: T. Patel, S. Yadav, and P. Shah. Investigations: T. Patel, N. Khanna, S. Yadav, and P. Shah. Writing original draft: T. Patel, N. Khanna, P. Shah, D. Singh, M. Gupta, and N. Kotkunde. Writing, review, and editing: all the authors. Supervision: N. Khanna. Funding: N. Khanna.

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Correspondence to Navneet Khanna or Munish Kumar Gupta.

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Patel, T., Khanna, N., Yadav, S. et al. Machinability analysis of nickel-based superalloy Nimonic 90: a comparison between wet and LCO2 as a cryogenic coolant. Int J Adv Manuf Technol 113, 3613–3628 (2021). https://doi.org/10.1007/s00170-021-06793-1

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