Journal of Manufacturing Processes 36 (2018) 44–50

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Journal of Manufacturing Processes

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Effect of different grinding fluids applied in minimum quantity cooling- T

lubrication mode on surface integrity in cBN grinding of Inconel 718
⁎
Anirban Naskar , Biddu Bhushan Singh, Amit Choudhary, S. Paul
Machine Tool and Machining Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal 721 302, India

A R T I C LE I N FO A B S T R A C T

Keywords: Inconel 718 (IN 718) is one of the important nickel based alloys that is being extensively used in aerospace
Surface integrity industry. Being an aerospace material, surface integrity is of paramount importance due to high risk factor
Residual stress involved in this kind of industry. Superabrasive grinding wheels are believed to be superior over conventional
Nickel based alloy wheels, which can improve the surface integrity of the ground component. Further, minimum quantity cooling
lubrication (MQCL) is seems to be a promising technique that can also yield desirable surface quality. Therefore,
in the present study IN 718 was ground with single layer superabrasive cBN wheel with neat oil, soluble oil water
emulsion and different nanofluids in MQCL mode, and the surface integrity was studied. Flood cooling was also
used as a benchmark. Residual stress, ground surface morphology, and surface roughness were studied using X-
ray diffraction, scanning electron microscope, and 3D surface profilometer, respectively. Chip morphology was
also studied using scanning electron microscope to correlate it with the surface quality of the job. Performance of
MQCL neat oil was found to be the best as compared to other fluids in the context of surface integrity due to
proper lubrication and grit penetration.

1. Introduction
The high fatigue strength of nickel based super-alloys even at high
operating temperature makes them an ideal choice for several in-
dustries including the aerospace sector. However, these alloys are dif-
ficult to machine/grind. Cracking, high tensile residual stress, surface
burn, and white layer formation are some of the major problems as-
sociated with machining such alloys [1–3]. Kovach and Malkin [4]
reported that microcracking may occur due to high tensile surface re-
sidual stress.
Liu et al. [5] used cBN, diamond and alumina wheels while grinding
Inconel 718 under flood cooling environment. They proposed a per-
formance index by amalgamating surface roughness, grinding ratio,
grinding force, and grinding temperature, for both rough and finish
grinding. The performance index was found to be higher for cBN and
diamond wheels as compared to conventional alumina wheel. They also
carried out cost analysis, which concluded that the diamond wheel was
better than alumina wheel even after considering the huge difference in
prices of the wheels. Cai and Rowe [6] ground Inconel 718 with dif-
ferent cBN wheels having different porosity and investigated the per-
formance of each wheel in flood cooling mode. The study showed that
wheels with higher porosity gave better surface characteristics due to
slower wheel loading and adequate transfer of cutting fluid. Also, high
porosity led to more frequent bond fractures that resulted in self-shar-
pening of grinding wheel. Patil [7] studied the grindability of Inconel
718 in flood cooling using the cBN wheel and found them suitable for
grinding Inconel. The effect of grinding on residual stress has not been
reported in the above studies [5–7]. Yao et al. [8] investigated the effect
of grinding on residual stress in Inconel 718 with flood cooling using
vitrified bonded single alumina (SA) wheel. The significant influence of
downfeed was observed on the affected layer. The affected depth of
residual stress of around 40–60 μm for 0.005 mm downfeed and
100–120 μm for 0.02 mm downfeed was found. For both the downfeed,
the surface residual stress was highly tensile in the range of
700–1000 MPa.
Flood cooling uses huge amounts of coolants that have a negative
impact on the environment and is an expensive process (can be as high
as 18% of the total manufacturing cost) [9]. Minimum quantity lu-
brication can serve as an alternative to the widely used flood cooling.
The advantages of MQL over the conventional cutting fluid includes
very low consumption of cutting fluid, less maintenance and disposal
cost of cutting fluid, and effective penetration of cutting fluid. Sinha

⁎
Corresponding author at: Machine Tool and Machining Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur,
West Bengal 721 302, India.
E-mail addresses: aniprit.09@gmail.com (A. Naskar), bhushan.biddu@iitkgp.ac.in (B.B. Singh), achoudhary@iitkgp.ac.in (A. Choudhary),
spaul@mech.iitkgp.ac.in (S. Paul).

https://doi.org/10.1016/j.jmapro.2018.09.023
Received 26 March 2018; Received in revised form 14 September 2018; Accepted 19 September 2018
Available online 26 October 2018
1526-6125/ © 2018 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
A. Naskar et al.
et al. [10] optimized experimental conditions to obtain the best results
in grinding of Inconel 718 with soluble oil water emulsion (1:20) ap-
plied in MQL mode using conventional alumina wheel. The document
provided the experimental parameters that produced least surface
roughness (flow rate at 150 ml/h, angular nozzle position at 15° and air
pressure at 8 bar). It was suggested that the standoff distance should
neither be too high nor too low. The droplet quality was observed to be
good at low flow rate (best at 150 ml/h). Grinding of Inconel 718 was
attempted with alumina wheel using different grinding fluids applied in
MQL mode [11]. Performance of ZnO and Ag nanofluids were com-
pared with dry grinding, wet grinding, and MQL with soluble oil water
emulsion. Improvement in grindability was observed while grinding
with nanofluids. Sinha et al. [12] performed dry grinding of Inconel
718 using conventional silicon carbide (SiC) and alumina (Al2O3)
wheels. The investigation concluded that Inconel 718 can be ground
more efficiently using alumina grinding wheels compared to the SiC
grinding wheel. This happened because silicon carbide wheels under-
went severe wear as it reacted with Inconel at higher temperatures.
Effect of different MQL parameters (air pressure and fluid flow rate)
was studied in the grinding of Inconel 751 with resin bonded diamond
grinding wheel [13]. Lowest surface roughness and normal grinding
force were observed at highest air pressure (6 bar) and lowest flow rate
of the fluid (60 ml/h) whereas lowest grinding temperature was found
at highest pressure (6 bar) and highest flow rate (100 ml/h). But they
[10–13] did not investigate the role of cooling-lubrication in MQL mode
on the residual stress on the ground surface.
It is quite apparent that the literature focusing on the surface in-
tegrity of IN 718 upon grinding using superabrasive wheels under
conventional cooling-lubrication environment is very scant. Further,
residual stress, which is a key factor of surface integrity, has not been
investigated in detail in MQCL grinding of IN 718. Therefore in the
present work, the effect of grinding of Inconel 718 with single layer
superabrasive cBN wheel under MQCL mode on surface integrity has
been investigated in detail. Three different nanofluids along with neat
oil and soluble oil water emulsion have been applied in MQCL mode.
Flood cooling has also been used as a benchmark. Residual stress along
with other surface integrity parameters such as ground surface mor-
phology, surface roughness has been studied. Chip morphology has also
been investigated to correlate it with surface quality.
2. Experimental details
Horizontal spindle plunge surface grinding of Inconel 718 was
carried out with monolayer electroplated cBN wheel using Cosmos
EARTH-6030 NC grinding machine. The dimension of work-piece was
8 mm × 8 mm × 25 mm. The grinding speed was 30 m/s, table speed
was 2 m/min and downfeed was 10 μm. Ten passes were taken for each
experiment. The mean of the observed forces in the last five passes was
considered to calculate the net tangential and normal force. The MQCL
parameters were: lubricant flow rate was 200 ml/h, gas pressure was
5 bar, horizontal stand-off distance was 20 mm, vertical stand-off dis-
tance was 15 mm and the angle at which the nozzle was inclined was
10° with horizontal.
0.1 v/v% nanofluids of MoS2, WS2 and hBN were prepared by
mixing the surfactant with nanoparticles in distilled water. The re-
sulting mixture was sonicated for 1 h to prepare a homogeneous na-
nofluid. Sodium Dodecyl Sulphate (SDS) was used as surfactant to im-
prove the stability of nanofluids. The composition of nanofluids has
been mentioned in Table 1. Soluble oil (Veedol – Solucut super) water
emulsion in 1:20 ratio was used both in MQCL and flood cooling mode.
Neat oil (HP – Trimofin 23) was also used in MQCL mode.
The normal and tangential grinding forces were measured using
piezoelectric dynamometer (Kistler – 9257B). X-Ray diffraction tech-
nique was used to measure residual stresses (PANalytical EMPYREAN).
The peak that was considered was at a nominal 2θ (diffraction angle)
value of 129.5° of (220) crystallographic plane with Cr X-ray target. The
45
Journal of Manufacturing Processes 36 (2018) 44–50
Table 1
Composition of Nanofluids.
Sl. No. Particle Density % volume Mass of Mass of
(g/cm3) concentration nanoparticle in surfactant in
100 ml of water 100 ml of
(in g) water (in g)
1 MoS2 4.8 0.1 0.4800 0.2400
2 WS2 7.5 0.1 0.7500 0.3750
3 hBN 2.29 0.1 0.2290 0.1145
reported values of residual stress are average of two measurements.
ZEISS SEM-EVO18 was used to observe the ground surface morphology
and the chip morphology. Surface roughness was measured using
Taylor Hobson-Form Talysurf-50 which is a 3D contact type surface
profilometer. The roughness values reported are average of ten surface
roughness profiles.
3. Results and discussion
3.1. Surface roughness and ground surface morphology
Ground surface morphology under different grinding environments
is shown in Fig. 1. Surface irregularities (e.g. ploughing) are presents in
each of the grinding environments even in flood cooling except for
MQCL neat oil. Ploughing is the sidewise displacement of the material.
The ploughed material remains attached to the groove generated by the
micro-cutting action of the abrasive grit. Fig. 2 shows schematically the
material that has been ploughed on both the sides of the grinding-
groove. The nature of schematic depiction of ploughing matches closely
with the actual SEM microphotograph as shown in Fig. 2(c). Often the
cutting action of an abrasive grit mechanically interacts with the al-
ready ground surface. Fig. 3 shows the effect of such ploughing sche-
matically and as a microphotograph obtained under SEM (Fig. 3(c)).
The ground surface generated under neat oil shows very little or no
ploughing (Fig. 1). Grinding marks are clearly visible on the ground
surface under neat oil that stands for material removal by proper
shearing. Cooling ability of the neat oil is expected to be lower than
other fluids [14]. Therefore, it can be directly attributed to the excellent
lubricating property of neat oil that enabled proper shearing action. For
a fixed grit geometry, ploughing to cutting transition occurs once it
reaches a critical rake angle [15]. It is known that high negative rake
angle promotes more ploughing action in grinding as compared to
cutting. There exists a critical rake angle below (less negative) which
cutting occurs and above which ploughing takes place. This critical rake
angle depends on the lubrication imparted by the grinding fluid. For a
better lubrication, cutting occurs even at higher negative rake as the
critical rake angle increases (more negative) with lubrication [15]. In
grinding, the rake angle of the grits is not same. It changes from grain to
grain due to random orientation. Therefore, it is suspected that grits
those failed to provide cutting due to high negative rake in poor lu-
brication medium, provided cutting with proper lubrication. Hence,
neat oil, which is expected to provide better lubrication, shows less
ploughing as compared to other fluids. It also supports MQCL as a
capable technique that makes the cutting fluid reach the grinding zone.
Among the nanofluids, hBN provided a ground surface with more
ploughing. This can be ascribed to agglomeration of hBN nanoparticles
at high temperature.
3.1.1. Correlation between ground surface morphology and surface
roughness parameters
Fig. 4 shows the effect of grinding environments on the different
surface roughness parameters and their ratios. Despite providing better
lubrication, arithmetic average surface roughness (Ra) of neat oil has
been found to be the highest as compared to other grinding environ-
ment as shown in Fig. 4(a) whereas lowest Ra is found for WS2
A. Naskar et al. Journal of Manufacturing Processes 36 (2018) 44–50

Fig. 1. SEM images of ground surface under different cooling lubrication conditions.

nanofluid. However, if the root mean square surface roughness (Rq) is n

1
compared from Fig. 4(b), neat oil provides comparable results as WS2. Rq = ∑ y2
n i=1 i (2)
To understand this discrepancy in the result of these two roughness
parameter, a careful observation is required on the mathematical for- As the formula shows in Eqs. (1) and (2), Ra is the average value of
mulae and on the ground surface morphology. all the peak and valley heights (yi) from the mean line whereas for the
calculation of Rq all the heights (yi) are squared first then the average
n
1 value gets square rooted. Therefore, Rq amplifies occasional high and
Ra = ∑ |y |
n i=1 i (1) low readings [16] and the increase in Rq will be more for surface with
peaks and valleys as compared to Ra. So, the surface with sudden peak

Fig. 2. (a) 3D view of ploughed surface, (b) top view, (c) experimentally observed surface by the action of a single grit.

46
A. Naskar et al.
Fig. 3. (a) 3D view of ploughed surface, (b) top view, (c) experimentally observed surface by the action of multiple grits.
and valley is expected to have higher Rq/Ra ratio than a surface with
uniform peak and valley height. For example, Fig. 5 shows roughness
profile of two typical surfaces. The case I is having a surface of uniform
peak and valleys whereas case II is a surface having some occasional
peaks and valleys. Therefore, based on the above discussion it can be
(
said that Rq Ra ) > Rq Ra
Case II
( )
.
Case I
Occasional peak and valleys are expected to be higher in the ground
surface with higher ploughing. Fig. 4(c) depicts Rq/Ra ratio for different
grinding environments. Neat oil shows comparatively lower Rq/Ra ratio
close to 1.1 as compared to other grinding environments which prove
that ploughing in case of neat oil was comparatively lower than others.
For other samples, it is above 1.2 which can be directly correlated to the
ground surface morphology that shows the presence of surface
Fig. 4. (a) arithmetic average surface roughness, (b) root mean square surface roughness, (c) ratio of Rq/Ra and (d) core roughness (Rk).
47
Journal of Manufacturing Processes 36 (2018) 44–50
irregularities e.g. ploughing. These surface irregularities amplify the Rq
and consequently, the Rq/Ra ratio also increases. This phenomenon can
be further supported by core roughness parameter (Rk). Rk is a measure
of core roughness (peak to valley) that excludes unusually high peaks
and deep valleys. In grinding, this parameter can be used to exclude the
peaks that can come due to ploughing or other irregularities generated
on the ground surface. Flood cooling and hBN nanofluid yield similar Ra
value like that under neat oil as can be seen in Fig. 4(a). But, the Rk
value obtained under neat oil is much higher than that under flood
cooling and hBN nanofluid (Fig. 4(d)). Higher Ra value along with
lower Rk value under flood cooling and hBN nanofluid can be ascribed
to more ploughing generating unusual high peaks. In case of neat oil,
higher Rk value can be attributed to higher grit penetration as discussed
in the next section.
A. Naskar et al. Journal of Manufacturing Processes 36 (2018) 44–50

Fig. 5. Schematic representation of two typical surfaces.

Fig. 6. (a) tangential and (b) normal grinding force under different grinding environments.

3.2. Grinding force and residual stress

Fig. 6 shows tangential and normal grinding forces of different

grinding environments. Neat oil shows maximum normal force and
second highest tangential force. This result is quite interesting and
contradictory as well to the earlier observation on surface morphology
in which it has been observed that neat oil performed better than others
due to its better lubricating nature. Better lubrication ability of neat oil
can also be confirmed by the tangential to normal force ratio (Ft/Fn).
For neat oil, it came to be 0.35 whereas for other fluids it is around 0.4
and above. Low force ratio in conjunction with clean ground surface
implies that higher grinding force for neat oil cannot be accounted
owing to inadequate lubrication. Therefore, it is being suspected that
higher forces are due to higher grit penetration in case of neat oil as
compared to other fluids. One can argue that for the same maximum
undeformed chip thickness (hm) grit penetration should remain same.
But, if the arithmetic average surface roughness (Ra) is observed (which
is a rough estimator of grit penetration), neat oil shows the maximum
surface roughness (Ra) despite having a clean ground surface which Fig. 7. Surface residual stress of different grinding environments.
clearly indicates that the grit penetration is more in case of neat oil. The
grit penetration of any grinding conditions cannot exceed the hm.
stress for all the used grinding environments. Residual stress has been
Therefore, it can be concluded that proper grit penetration occurred
found to be minimum while grinding with neat oil. Usually, residual
during grinding with neat oil. Further, confirmation of this correlation
stress becomes less tensile with the reduction in grinding temperature
between grinding force and Ra can be drawn by observing the force and
or with the increase in plastic deformation due to the mechanical cut-
Ra value obtained while using WS2 nanofluid. WS2 nanofluid shows
ting action of the grits [17]. Lower residual stress for neat oil can be
minimum Ra along with minimum tangential force and second lowest
attributed to the proper mechanical action of the grits. Highest normal
normal force. It indicates that grit penetration is lower for WS2 than
grinding force in conjunction with clean ground surface stands for
other fluids, which is responsible for lowering the force. Hence, lower
proper grit penetration during grinding with near oil. Further, it is
grinding force and lower average surface roughness (Ra) cannot be
expected that the grinding temperature remains comparable under neat
made as an indicator of better grindability without considering other
oil with respect to other grinding fluids. Neat oil has less cooling-ability
aspects.
due to its lower thermal conductivity as compared to water based
Another justification of proper grit penetration during grinding with
grinding fluids [14]. But its enhanced lubrication ability is expected to
neat oil is obtained from the residual stress. Fig. 7 shows the residual

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A. Naskar et al. Journal of Manufacturing Processes 36 (2018) 44–50

Fig. 8. Typical serrated chip obtained while grinding Inconel 718 using single
layer electroplated cBN grinding wheel under flood cooling.

compensate for its lower cooling-ability and provide similar grinding

temperature. For the same soluble oil water emulsion that has been
used in flood cooling and MQCL mode, flood cooling yields lower re-
sidual stress as compared to MQCL. Convective heat transfer co-effi- Fig. 10. variation of cutting stain with coefficient of friction at the chip-tool
cient under flood cooling is much higher than MQCL [18]. This in- interface.
dicates that the higher heat transfer co-efficient of flood cooling is
responsible for better cooling that has provided less tensile residual
3.3. Chip study
stress as compared to MQCL. Nanofluids have provided much higher
residual stress as compared to other fluids. This may be due to the in-
Serrated chips are found for all the grinding environments. One such
sufficient cooling and lubrication ability of the nanofluids owing to
image of the serrated chip is shown in Fig. 8. Typically, nickel-based
agglomeration.
alloy provides long chip owing to their high ductility [14]. Flowing type
long chips have been found for flood cooling, neat oil and soluble oil

Fig. 9. SEM images of chip morphology that formed during grinding under different environments.

49
A. Naskar et al.
water emulsion whereas very short broken type of chips are observed
during grinding with all nanofluids as shown in Fig. 9. Flowing type
chip forms in grinding of IN 718 if grits are very sharp [19]. Single layer
superabrasive cBN wheel which has been used in the present study is
considered to be one of the sharpest wheels among the others which
justify the flow type chip formation. Flow type chip formation was also
correlated with the best surface quality in the same study [19]. Residual
stress is one of the most crucial aspects of surface quality. Lowest re-
sidual stress has been observed in the earlier section for neat oil fol-
lowed by flood cooling and soluble oil water emulsion. Neat oil, flood
cooling and soluble oil water emulsion produced flow type chip that
supports the correlation between flow type chip and good surface
quality. Chip produced by nanofluids in the present study are found to
be broken type that contradicts to an earlier research [11] in which
flow type chips were observed for nanofluids. Broken type of chips has
been observed in this study for all the three nanofluids irrespective of
the surface quality of the job.
Chip breaking occurs when the cutting strain reaches a limit [20].
The cutting strain can be obtained from Eq. 3. A direct correlation
between cutting strain and co-efficient of friction at the chip-tool in-
terface (μ) can be obtained by combining Eqs. 3–5 which is expressed as
Eq. 6. Fig. 10 shows this correlation in a graphical way while γo (rake
angle) has been considered as –60°. It shows that cutting strain in-
creases with the increase in co-efficient of friction. It means that with
the increase in μ, probability of chip breaking increases. It seems na-
nofluids failed to provide proper lubrication in the chip-tool interface
which provided the broken type of chips.
εc = cot β + tan(β−γo) (3)
cos γo
tan β =
ζ − sin γo (4)
π
ζ= e μ ( 2 − γo) (5)
cos γo
π π −tan γo
e μ ( 2 − γo)−sin γo e μ ( 2 − γo) − sin γo
εc = + cos γo tan γo
cos γo 1 + μ ( π −γ )
e 2 o − sin γ
o (6)
4. Conclusions
In the present research, an attempt has been made to study the ef-
fect of different grinding fluids applied in MQCL mode on the grind-
ability of Inconel 718. Based on the above results and discussion some
major conclusion can be drawn:
• Neat oil could produce a clean ground surface with very less
ploughing as compared to other fluids.
• Neat oil shows lowest Rq/Ra ratio owing to its uniform surface
roughness.
• Coefficient of friction was minimum for neat oil.
50
Journal of Manufacturing Processes 36 (2018) 44–50
• Residual stress was found to be minimum for neat oil followed by
flood cooling.
• Flood cooling, MQCL neat oil, and soluble oil water emulsion pro-
duced the flowing type of chip whereas broken small chips were
observed for all the nanofluids.
• Performance of MQCL neat oil was found to be most favourable as
compared to other fluids.
Acknowledgement
The research did not receive any specific grant from funding
agencies in the public, commercial, or not-for-profit sectors.
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