Journal of Manufacturing Processes 103 (2023) 156–167

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Journal of Manufacturing Processes

journal homepage: www.elsevier.com/locate/manpro

Comprehensive analysis of tool wear, surface roughness and chip

morphology in sustainable turning of Inconel-601 alloy
Mehmet Erdi Korkmaz a, Munish Kumar Gupta b, c, *, Mustafa Günay a, Mehmet Boy d,
Nafiz Yaşar e, Recep Demirsöz a, K. Nimel Sworna Ross f, Yasir Abbas a
a
Department of Mechanical Engineering, Karabük University, Karabük, Turkey
b
Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland
c
Department of mechanical engineering, Graphic Era (Deemed to be university), Dehradun, India
d
TOBB Vocational High School, Karabük University, Karabük, Turkey
e
Department of Mechanical Engineering, Dumlupınar University, Turkey
f
Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, Johannesburg, South Africa

A R T I C L E I N F O A B S T R A C T

Keywords: The objective of this research was to explore the impact of various cooling conditions on machinability, as
Tool wear potential alternatives to traditional cooling methods. To achieve this aim, a series of experiments were per­
Surface roughness formed, where dry machining, minimum quantity lubrication (MQL), nanofluids, cryogenic (cryo) cooling, and
Cooling
hybrid cooling (cryo+nano MQL) methods were tested. Under distinct nanofluids conditions hBN(0.2 %) +
Sustainable manufacturing
Tribology
graphene(0.2 %) performed well and overall cryo+nano MQL produced better result in terms of tool wear,
microhardness, surface and chip morphology. The results demonstrated that the cooling effect of the Cryo-MQL
regime, which maintains the cutting temperature at a tolerable level and preserves the lubricant performance of
the MQL, is the cause of the lowest Vb value of 90 μm.

1. Introduction
In machining, the relative motion and cutting force between the
insert and workpiece are necessary for chip formation. Friction, which
occurs due to the action and force effect, causes an increase in temper­
ature. Heat is generated by internal frictions in the primary deformation
region, internal and external frictions in the secondary deformation re­
gion (tool-chip interface), and friction and deformation between the
machined surface under the tool cutting edge and flank side [1]. This
heat, and therefore temperature, causes a decrease in hardness, in­
creases tool wear, shortens life, and may cause plastic deformation of the
tool [2]. In machining, cutting tools complete their life by wear down,
undergoing plastic deformation or breaking. As the tool reaches the end
of its life, deviations occur in the machined part dimensions and the
surface quality decreases [3]. At this stage, the tool must be replaced and
for that purpose, different methods are used in factories and laboratories
to predict tool life. There are many parameters such as workpiece ma­
terial type, tool type, cutting speed, feed rate, depth of cut, heat
generated, coolant and machine construction affecting the surface
roughness in machining. With the change of one of these factors, the
surface roughness also changes [4]. In general, flank wear (tool surface
in contact with the machined surface) is used as a criterion because it is
the type of wear that usually determines surface roughness and accu­
racy. Depending on time, first the flank wear is dominant, but after a
long time, crater wear takes the lead and becomes the life criterion.
Factors such as high stresses and temperatures during chip removal, chip
sliding on the rake face and sliding of the free surface on the chipped
workpiece cause wear on the cutting tool [5]. Tool wear adversely up­
sets tool life, the machined surface quality, dimensional precision and
ultimately the economy of the cutting process [6].
In order to keep up with the rising need for high levels of produc­
tivity in the machining industry, cutting and feed rates have to be
increased. When cutting, naturally high temperatures are generated,
which not only shortens the life of the tool but also decreases the product
quality. The utilization of cutting fluids, which are characterized by
advantageous machining, lubricating, and cooling qualities, makes a
constructive role to the overall machining performance [7]. However, a
negative aspect of cutting fluids is that the quality decreases with use.
Cutting fluids become contaminated with foreign substances over time.
When the fluid loses its function, it becomes waste [8]. As a result, the

* Corresponding author at: Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45-758 Opole, Poland.
E-mail address: m.gupta@po.edu.pl (M.K. Gupta).

https://doi.org/10.1016/j.jmapro.2023.08.026
Received 1 April 2023; Received in revised form 27 June 2023; Accepted 9 August 2023
Available online 26 August 2023
1526-6125/© 2023 The Author(s). Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers. This is an open access article under the CC BY
license (http://creativecommons.org/licenses/by/4.0/).
M.E. Korkmaz et al.
Table 1
The chemical composition of the Inconel 601.
Ni(%) Cr(%) S(%) Mn(%)
~58–63 ~21–25 ~0.015 ~0.01
expenditures made for cutting fluids in companies constitute a large part
of the total machining cost. Fluid expenses account for between 7 % and
17 % of overall production costs, whereas tooling costs account for just
4 % [9]. This disparity has recently begun to shift. Installing a fluid
supply system, purchasing fluid, maintaining the system, and treating
fluid waste are all examples of fluid-related costs. Reducing the amount
of fluid used can result in substantial cost and waste savings, as high-
output manufacturing facilities often use multiple cutting fluid reser­
voirs, each containing thousands of gallons of cutting fluid. When
quality issues arise, it is not uncommon for an entire reservoir to be
flushed to clean the system [9].
Three techniques are used for reducing the use of cutting fluid. These
are cutting without using cutting fluid (dry cutting), especially high-
speed cutting (High Speed Machining) and minimum quantity lubrica­
tion (MQL) techniques [10]. Although dry cutting is currently being
used successfully as an environmentally friendly manufacturing method,
this method may be less efficient when high machining efficiency,
Fig. 1. Experimental setup used in the work.
Journal of Manufacturing Processes 103 (2023) 156–167
Al(%) C(%) Cu(%) Si(%) Fe(%)
~1.0–1.70 ~0.01 ~1.00 ~0.50 Bal.
superior surface quality and difficult cutting situations are desired. For
such cases, a MQL method, also called near dry machining, has been
developed [11]. Moreover, the methods for increase of viscosity can be
tried for thicker oil film between the workpiece and the cutting tool
[12]. There are two options: i) increase base oil viscosity by adding
nanoparticles into it (nano-lubricants / nano-MQL), ii) increase base oil
or nano-MQL viscosity by decreasing the temperature of the oils [13]. In
nanofluids formed from nanoparticles larger than 10 nm, the viscosity
increases as the concentration increases, and decreases as the temper­
ature rises [14]. However, the viscosity value of the nanofluid is always
high to the base fluid. Reducing the size of the nanoparticles for a given
concentration increases the viscosity as it creates a higher solid surface
area.
Some literature studies about machining under different cutting
environments like MQL [15], cryogenic [16] and hybrid cooling/lubri­
cation [17] are summarized below. Gajrani [18] performed Ti6Al4V
turning via uncoated carbide under dry, MQL, and cryo-MQL conditions.
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Table 2
The cutting parameter levels and carbide insert specifications.
Cutting
Levels
parameters
Cutting speed 60 80 100
Feed rate 0.8 0.12
Depth of cut 0.25
Nano-
Nano- Nano- Cryo-
MQL3
Cutting media Dry MQL MQL1 MQL2 Cryo nano-
(graphene
(graphene) (hBN) MQL
+ hBN)
Carbide inserts CNMG120404-PM4225 – Tool nose radius 0.4 mm

The authors evaluated that the surface quality, insert wear and cutting to deliver the nanoparticles in equal numbers per unit area, the nano­
forces decreases with cryo-MQL condition. Nagaraj et al. [19] conducted particles were supplied in close sizes and added to the cutting fluid on a
drilling experiments of CFRP composite via dry, MQL, cryogenic, and weight basis. The hBN used is a white fluffy light powder with a large
cryo-MQL environments. They assessed the surface quality, tool life is surface area, 40–50 nm in size.
better under cryogenic, and cryo-MQL conditions than dry and MQL
cutting environments. Khan et al. [20] performed turning experiments
2.1. Testing procedure/sequence
for Ti6Al4V via cemented carbide tools in MQL, flood, and cryo-MQL
environment. The authors emphasized that surface roughness, insert
✓ Solid nanoparticles were added to the Werte branded WerteOil
wear and energy consumption can be decreased via cryo-MQL cooling/
vegetable-based oil. The company of Werte Oils suggested this type
lubrication condition. Sun et al. [21] performed the end milling of
of vegetable oil for cutting nickel-based superalloys.
GH4099 superalloy in dry and MQL environments and highlighted MQL
✓ Magnetic stirring, mechanical mixing and ultrasonic mixing pro­
is better than dry conditions based on surface quality, insert wear and
cesses were applied to the nanoparticle added mixture in order to
cutting force.
make the nanofluid mixture homogeneous. Thus, a homogeneous
In the light of the given information, the studies about insert wear in
and delayed collapse nanofluid was obtained. The homogeneous
machining are generally based on comparison between dry, MQL,
nanofluid has been directly used after mixing.
cryogenic, or cryo-MQL. In addition to these known procedures, as a
✓ Precision Balance was used for nanoparticle and MQL coolant
novelty, this study also focused on using both different types of nano-
amount variations.
MQL and cryogenic nano-MQL to rise the viscosity of the base oil (for
✓ LN2 cooling at 0.2 bar is supported for cryogenic cooling produced
thicker oil film) as well as to decrease the friction and heat between the
by Low-Temp Company. The lubrication and cooling environments
workpiece and the insert. In this context, detail tool wear analysis and
named as MQL, nano-MQL, cryo and cryo-nano-MQL system are
mechanisms, also different observations of critical tool flank and crater
shown in Fig. 1.
wear were evaluated in environmentally friendly turning of nickel-based
✓ Turning tests have been performed with mentioned cutting
superalloy. Moreover, roughness of the machined surface, chip
parameters.
morphology, microstructures and microhardness of machined work­
✓ The machine setup has been cleaned after each step of turning
piece have also been analyzed. Finally, comprehensive images of SEM
process.
and also EDX/MAP analysis were performed for the evaluations of insert
✓ Surface roughness measurements were done based on ISO 4287
wear.
standard. Arithmetical mean roughness height (Ra) values were
taken into account. The surface roughness measuring device used is
2. Materials and methods
the Mahr Perthometer-M300 branded portable measuring device.
✓ Tool images by Scanning Electron Microscope (SEM) has been per­
In the experiments, commercially available Inconel 601 Ø60×200
formed by Nikon-Carl Zeiss branded SEM device and also Energy-
mm was used. The chemical composition of the material are presented in
dispersive X-ray spectroscopy (EDX) and MAP demonstration has
Table 1. Machining experiments were carried out using a Taksan-
been performed to understand better the adhesive and abrasion sit­
TTC550 CNC lathe in the Manufacturing Engineering laboratory of
uations on the cutting inserts.
Karabük University. Kyocera brand carbide cutting inserts (CNMG 12 04
✓ The samples prepared to take the microstructure image were
04-MF) were used in the experiments. The experimental equipment is
immersed in a Inconel etchant consisting of Nitric Acid, Hydrochloric
displayed in Fig. 1. The cutting parameter levels and carbide insert
acid, H2O2 (30 %), Distilled Water by 50 ml, 75 ml, 35 ml, 90 ml for
specifications are tabulated in Table 2. Werte branded WErtex15 model
25 s, respectively.
cooling system, which is suitable for external cooling applications, is
✓ The measurement of microhardness for the samples have been per­
used as the MQL system. This system is suitable for almost all work­
formed by Qness branded Vicker Microhardness test setup.
benches and enables experiments to be carried out easily. To increase
the performance of the MQL system, 0.2 % nanoparticles were added to
the cutting oil by suggestion of some literature studies [22]. Graphene 3. Results and discussions
and hBN nanoparticles were used to prepare nanofluids in the study. In
addition, a total of 0.2 % nanoparticle (graphene 0.1 % + hBN 0.1 %) 3.1. Tool wear
was added to obtain a hybrid nanofluid. While preparing the nanofluid
The most commonly considered indicator in assessing tool life is

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Fig. 2. The formation of flank and crater wear in a cutting insert.

Cooling conditions
Dry_ MQL nano_MQL_1 nano_MQL_2 nano_MQL_3 Cryo_ Cryo_Nano_MQL

280 280
Feed rate: 0.08 mm/rev Feed rate: 0.12 mm/rev

240 240

200 200
Tool wear, µm
Tool wear, µm

160 160

120 120

80 80

40 40

0 0
60 80 100 60 80 100

Cutting speed, m/min Cutting speed, m/min

Fig. 3. Tool wear values under different cutting conditions.

flank wear (Vb) and crater wear as displayed in Fig. 2. Fig. 3 displays the
flank wear changes according to the cutting parameters thereafter 8 min
turning of the workpiece under different cutting regimes. After 8 min,
the tool was worn at the dry condition. That duration has been deter­
mined as the base duration in turning operations. The turning process at
the other environments has been performed by 8 min for comparison. In
general, it is understood that the flank wear tends to be similar in terms
of cutting regimes at both feed rates. The increment in feed rate in­
creases the chip cross-section, increasing the cutting resistance and thus
the mechanical loads to which the tool is exposed. As a result, the
increased abrasive wear mechanism, especially in dry cutting, causes
acceleration of flank wear [23]. In the presented study, the high Vb
values in the dry cutting regime are attributed to the rapid removal of
the tool coating owing to the large thermo-mechanical effect during
cutting and the subsequent formation of Built-up-Edge (BUE). The
increased ductility of the machined material is a direct result of the high
temperatures generated during dry cutting. This is because the
machined material has a limited heat conductivity and a property that
causes it to strain harden. Because of this process, there was a greater
rise in the development of BUE along the adhesive wear mechanism,
namely the insert edge. That is to say, since there was no impact of
cooling or lubrication present during this regime, the process of flank
wear was accelerated by going through a cycle of development and
rupture of the BUE. From Fig. 3, it is observed that Vb values increment
proportionally with 50 % rise in feed. In this context, the maximum Vb
was measured as 244 μm in dry cutting environment at 100 m/min
cutting speed and 0.12 mm/rev feed. It is seen that the flank wear rises
with increasing the cutting speed, and in the literature, this result is
attributed to the rising temperature with increasing the cutting speed.
When the Fig. 3 is examined carefully, the effect of increasing cutting
speed becomes more evident in dry, MQL and Nano-MQL2 cutting re­
gimes at f = 0.08 mm/rev. Namely, increasing friction time at low feed
causes the shear temperature to increase further, resulting in a decrease
in the viscosity of the MQL fluid. This formation resulted in increased
wear of Vb by reducing the lubricating film in MQL and the lubricating
and microbedding effect in Nano-MQL2. As a matter of fact, the highest

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Fig. 4. Tool wear SEM (with EDX and MAP) under different cutting environments at the cutting speed of 100 m/min and the feed rate of 0.12 mm/rev.

160
M.E. Korkmaz et al.
Fig. 4. (continued).
Vb value after dry cutting was measured as 194 μm in MQL cutting
medium at V = 100 m/min and f = 0.12 mm/rev. Among the nano­
particle cutting regimes, the lowest Vb values were obtained in the
Nano-MQL-mix medium. In the presented study, the increase in chip­
ping and breakage on the cutting-edge following flank wear can be
ascribed to the polishing/rubbing effect of nanoparticles. As expected,
Vb values were lower due to the cooling effect providing by the Cryo and
Cro-MQL regimens. The lowest Vb value (90 μm) is a result of the
coolant effect of the Cry-MQL regime, keeping the cutting temperature
at a reasonable level and thus not losing the lubricant performance of the
MQL.
Further, the tool wear mechanism with the help of SEM and EDX
analysis was performed on the worn cutting tools, as shown in Fig. 4.
The results of SEM images taken from the tool rake surfaces show the
presence of Built-up-Layer (BUL) and BUE formations in all cutting
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Journal of Manufacturing Processes 103 (2023) 156–167
regimes. It is seen that BUL formation is more concentrated in the 3rd
region (sticking) of the rake face with increasing feed, which can be
ascribed to the increment in the adhesion tendency with decreasing
temperature towards the said region [24,25]. Indeed, EDX analyzes from
different parts of the teams confirm these inferences. However, BUL
formation appears to be lower in the MQL regimen than in other shear
media. From this, it can be said that the lubricating film-forming prop­
erty of the cutting medium is more efficient than the high cutting speed
in reducing the formation of BUL and BUE. The lubricating film layer
formed at tool-chip contact surface in Nano-MQL and Cryo cutting re­
gimes reduced the abrasive wear effect and reduced the Vb value, as
mentioned in the literature [26]. Moreover, as can be realized from
Fig. 4, it is seen that especially in cutting environments with Nano-MQL,
the fractures are concentrated at the crossing of the tool rake and flank
surface. In the literature, the rubbing effect of particles in nanoparticle
M.E. Korkmaz et al.
Cooling conditions
Dry_ nano_MQL_2 Cryo_
MQL nano_MQL_3 Cryo_Nano_MQL
nano_MQL_1
0.8
0.75
0.7
0.65
Surface roughness, µm
0.6
0.55
0.5
0.45
0.4
0.35
0.3
60 80
Cutting speed, m/min
(a)
Fig. 5. Surface roughness under cutting environments; (a) f = 0.08 mm/rev and (b) f = 0.12 mm/rev.
reinforced shear regimes is mentioned [27].
3.2. Surface roughness analysis
Arithmetical mean roughness height (Ra) is the most considered
roughness criterion in terms of both mechanical properties and surface
integrity of machined parts. The surface roughness changes during
turning of Inconel601 alloy in seven different cutting regimes are pre­
sented in Fig. 5. The primary thing to notice is that Ra values increase
with increment feed from 0.08 mm/rev to 0.12 mm/rev, as expected.
The 50 % increase in feed resulted in 60 % and 68 % increases in surface
roughness at the minor cutting speed in dry and MQL cutting regimes,
while this ratio was 136 % and 112 % at the major cutting speed. In
Nano-MQL, Cryo and Cryo-MQL cutting environments, the rate of in­
crease in Ra value is over the range 100–114 % at the lowest cutting
speed, while these rates are in over the range 86–93 % at the highest
cutting speed. That is, the lubrication and/or cooling effect provided by
Nano-MQL, Cryo and Cryo-MQL cutting media at high cutting speed
resulted in a reduction in Ra values [28,29]. As it is well known from the
literature [30], the Ra value changes in direct proportion to the feed in
turning operations (Ra = f2/32r, r = nose radius). Another reason is that
more machining scars are formed on the machined surface due to
improved tool flank wear with increasing feed and cutting speed. When
Fig. 5a and b are observed, it is clearly understood that Ra values in­
crease with increasing cutting speed in all cutting regimes. This result
can be explained by the machining process, where increased cutting
speed and feed cause peeling of the tool coating and subsequently
accelerating tool wear. While the rise in cutting speed is expected to
reduce the formation of BUE, high temperatures accelerate tool wear
and the increase in friction and pressure in the tool-workpiece interface
increased the tendency of chip adhesion. As can be observed from Fig. 4,
the increased BUE on the tool flank and rake face caused a change in the
active rake angle of the insert and an unstable cutting process, resulting
in a decrease in surface quality, as mentioned by Pervaiz et al. [31].
Therefore, in both feeds, the worst surface quality occurred in the dry
Journal of Manufacturing Processes 103 (2023) 156–167
Cooling conditions
Dry_ nano_MQL_2 Cryo_
MQL nano_MQL_3 Cryo_Nano_MQL
nano_MQL_1
2
1.8
1.6
Surface roughness, µm
1.4
1.2
1
0.8
0.6
0.4
100 60 80 100
Cutting speed, m/min
(b)
cutting regime, while the highest Ra value was 1.80 μm at V = 100 m/
min and f = 0.12 mm/rev. On the other hand, it is seen that the
roughness decreases from the dry cutting regime to the Cryo-MQL
regime, and this result is more pronounced at high feed. Thanks to the
more lubricating effect of MQL and nano-MQL media, cutting occurs
more easily in the second deformation zone (tool-chip interface), as
contact length and thus frictional resistance are reduced [32]. This
formation improves surface roughness as can be shown in Fig. 6 (a) and
(b) by reducing cutting forces and tool vibrations. A similar formation
occurs with the cooling influence providing in the Cryo cutting regime
by Fig. 6c. The reduction in chip bend radius and segmentation ratio due
to cooling, and thus the reduction in tool-chip interface friction resis­
tance, resulted in an improvement in roughness. Since this phenomenon
prominently appeared in the Cryo-MQL medium, the minimal surface
roughness was measured as 0.36 μm at a cutting speed of 60 m/min and
feed of 0.08 mm/rev.
3.3. Chip morphology
Factors such as the chip type formed during the machining, the type
of material removed, the tool geometry, the chip removal method
applied, and the cutting parameters constitute a factor in the formation
of the shape of the removed chips [33]. The types of chips formed also
give us information about cutting conditions, whether chip removal is
difficult or easy, and surface quality. In the case of machining ductile
materials like nickel based superalloys with low or medium cutting
speeds (dry machining), it caused the workpiece to stick to the cutting
edge of the machining surface to a certain extent (BUE) due to the
rubbing on the surface between the tool and chip [34]. This formation
occurred in the form of a cycle and the bond between the tool weakened
and broke [35]. The accumulation of chip during machining of Inconel-
601 and the rupture of the formed accumulation occurred in a short
time, and a large amount of plastered chips (Table 3) covered the
machined surface [36]. At the end of the adhesion, it caused a notch
effect on the machined surface, causing the surface quality to
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Fig. 6. Machined surface SEM images under different machining environments (a) Dry and MQL conditions, (b) Nano-MQL environment (c) Cryo and Cryo-Nano-
MQL environment at the cutting speed of 100 m/min and the feed rate of 0.12 mm/rev.

deteriorate. The continuous chips have occurred caused by the low
friction between the tool and chip by the help of MQL, all of nano-MQL
situations and also cryo-nano-MQL conditions [37]. When ductile ma­
terials like Inconel-601 are machined, the plastic deformation that oc­
curs in the material was caused by the sliding of many crystals on the
shear plane. The occurrence of these chips showed us that a workpiece
with a good surface quality was formed with MQL, nano-MQL and cryo-
nano-MQL conditions [18], and this is seen in Table 3. In metals with
low thermal conductivity, serrated chips were formed due to the rapid
decrease in strength due to the increase in temperature during
processing. The developments in the material types and cutting tool
materials have caused the formation of serrated chip type in dry envi­
ronments without lubrication and cooling. Serrated chip formation has
occurred in machining operations such as nickel-based alloys with low
thermal conductivity, where the cutting process is performed in difficult
and non-lubricated environments (dry machining) [38].
3.4. Microstructure and microhardness
Machining is a serious plastic deformation process that leads to

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Table 3
Chip morphology under different machining environments.
Sr. no. Cooling condition Types of chips Image of chips SEM images of chips

1 Continuous chip
(Entanglement)

2 Continuous chip
(Entanglement)

3 Continuous chip
(Entanglement)

4 Continuous spiral chip

5 Continuous spiral chip

6 Discontinuous chip
(Entanglement)

7 Discontinuous spiral chip

alteration of microstructure and material features as a result of hetero­
geneous thermo-mechanical deformation of metal at high deformation
rates [39]. After machining, the mechanical behavior of material based
on considerations such as microstructure, stress and strain state, and
these parameters are caused by thermal changes that change according
to the cutting conditions [40]. In this context, estimation of thermo­
mechanical changes is important when machining difficult-to-machine
materials under sustainable cutting regimes [41]. The microstructure
images taken from the machined surfaces after 8 min turning on Inconel
601 alloy are given in Fig. 7.

164
M.E. Korkmaz et al.
Fig. 7. Microstructure images under the different cutting environments (Modified from [42]).
The maximum hardness was obtained at 100 μm depth from the
machined surface in all cutting environments, the highest microhard­
ness was 256 μm in the Cryo cutting regime, while the lowest micro­
hardness was found at 200 μm in the dry environment (Fig. 8). The high
microhardness near the machined surface is the outcome of thermo-
mechanical loads during cutting and strain hardening as a result of
plastic deformation [43]. The excessive cutting temperature in the dry
cutting environment caused softening in the material, preventing
hardening due to plastic deformation as well as a coarser grained
structure. As can be seen from Fig. 8, the fine-grained microstructure
near the machined surface in a dry and MQL environment is an indi­
cation of the increase in microhardness. Grain thinning is a combination
of hardness transformation temperature and plastic deformation, which
varies depending on cutting parameters and environments, as
mentioned in the literature [44]. At this point, the small thermal con­
ductivity of the work material means that the heat generated in the
cutting zone is reduced in propagation towards the material core. Thus,
more severe plastic deformation occurs near the surface, contributing to
the formation of fine-grained structure. On the other hand, the increase
in material tensile strength due to the sudden cooling provided by the
Cryo and MQL cutting regimes also means an increase in plastic defor­
mation. In this case, the fine-grained structure will cause an increase in
microhardness, again close to the machined surface. It is thought that
the above-mentioned phenomenon occurs thanks to the heat carrying
capacity of the particles in nano-MQL environments. As a matter of fact,
the microhardness values obtained in these environments are between
Cryo and pure MQL cutting regime.
4. Conclusions
During the turning of Inconel 601, the purpose of this research was to
explore the influence that various cooling approaches have on the
temperature of the tool-chip contact, surface roughness, and tool wear.
The purpose of the study was to evaluate the practicability of cooling
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Journal of Manufacturing Processes 103 (2023) 156–167
technology from a technical and ecological standpoint. Throughout the
course of the studies, a variety of various approaches to cooling were
utilized, including dry, MQL, nMQL (graphene, hBN, graphene+hBN),
cryo-LN2, and hybrid conditions. The results of the experiment were
analyzed in depth and the following findings were reached:
• The application of cooling techniques during turning has greatly
improved the machining performance of Inconel 601. With cryo-
nMqL condition, there has been a noticeable decrease in flank
wear. Due to the chilling effect of the Cryo and Cryo-nMQL C/L
régimes, Vb values were lower as was to be predicted. Based on SEM
analysis, tool flank wear under dry condition shows adhesion and
severe wear. NMQL3, among nanofluid condition reduced the wear
mechanisms by reducing the tool-work junction friction. However,
the best condition to reduce the wear was cryo-NMQL.
• The rate of rise in Ra value in the Nano-MQL, Cryo, and Cryo-MQL
cutting settings ranges from 100 to 114 % at the minimal cutting
speed to 86 to 93 % at the maximum cutting speed. In other words,
Ra values diminished of the lubricating and/or cooling impact given
by Nano-MQL, Cryo, and Cryo-nMQL cutting media. Dry and MQL
produces highest Ra value in relation to other conditions.
• With the aid of MQL, all nano-MQL scenarios, and cryo-nano-MQL
conditions, continuous chips have developed as a result of the
reduced friction amid the tool and the chip.
• A coarser grained structure and hardening owing to plastic defor­
mation was prevented by the material softening in consequence of
the dry cutting environment's high cutting temperature. However,
the abrupt chilling and lubrication brought on by the Cryo and nMQL
cutting regimes, which increases material tensile strength, simulta­
neously causes a rise in plastic deformation. In this instance, the
microhardness will rise as a result of the fine-grained structure.
M.E. Korkmaz et al.
260
240
Microhardness (HV)
220
200
180
160
0 100 200
Depth from machined surface (µm)
Fig. 8. Micro-hardness values based on cutting conditions.
Declaration of competing interest
The authors declare the following financial interests/personal re­
lationships which may be considered as potential competing interests:
The work presented in this paper is, to the best of my knowledge and
belief, original, except as acknowledged in the text, and the material has
not been submitted, either in whole or in part, for a degree at this or any
other university. There is no conflict of interest to declare.
Acknowledgement
The authors thank to Karabük University Scientific Research Projects
Coordination with a project number KBÜBAP-22-DS-141.
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