INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11, pp.

1689-1697 NOVEMBER 2018 / 1689

REGULAR PAPER DOI: 10.1007/s12541-018-0196-7

ISSN 2234-7593 (Print) / 2005-4602 (Online)

Environment Friendly Machining of Inconel 625 under

Nano-Fluid Minimum Quantity Lubrication (NMQL)

Talwinder Singh1, Jasminder Singh Dureja1,#, Manu Dogra2, and Manpreet S Bhatti3
1 Department of Mechanical Engineering, Punjabi University Patiala, India
2 Department of Mechanical Engineering, S S Giri, Punjab University Regional Center, Hoshiarpur, Punjab, India
3 Department of Botanical and Environmental Sciences, Guru Nanak Dev University, Amritsar, Punjab, India
# Corresponding Author / E-mail: jsdureja73@gmail.com, TEL: +91-9501017513
ORCID: 0000-0002-9851-3968

KEYWORDS: Environment friendly machining, Inconel 625, Multiwall carbon nanotube (CNT), Nano-fluid minimum quantity lubrication (NMQL), Surface roughness (Ra), Tool flank wear (VB)

Superalloy Inconel 625 although having many industrial applications owing to its high strength, exhibits poor machinability because
of its sticky nature and poor heat conductivity. To improve its machinability, use of cutting fluids becomes necessary to remove heat
and provide lubrication in the cutting region. However, harmful effects of cutting fluids on environment and operator health restrict
their application. Several efforts have been carried out to replace or minimize the quantity of conventional cutting fluids used in
machining to strive for green machining and economizing machining operations. Nano-fluid minimum quantity lubrication (NMQL)
technique has evolved as best alternative to flood conditions cooling / lubrication especially for machining of alloys like Inconel. This
paper experimentally investigates the suitability of NMQL (carbon nanotube; CNT in vegetable oil) in machining of Inconel 625. The
objective was to minimize tool wear and surface roughness under different machining conditions. Tool performance in NMQL was also
compared with that under dry and flood conditions. The results revealed superiority of NMQL in terms of better tool life and improved
surface finish over dry machining and nearly equivalent performance to wet (flood) machining thus provides the way forward for
sustainable and environmental friendly machining.

Manuscript received: February 16, 2018 / Revised: July 2, 2018 / Accepted: August 13, 2018

1. Introduction In order to overcome these problems, application of cutting fluids

Nickel-based aerospace alloys are gaining substantial attention
because of their admirable mechanical properties, excellent weldability,
high corrosion and oxidation resistance etc. Inconel 625 is one of these
super alloys, widely used in manufacturing sectors, particularly for
aerospace components, gas turbine blades, springs, bellows for
submarines, steam power plants and oceanographic instrument
1
components. However, machinability of Inconel 625 is considered to
be poor because of its poor heat conductivity, formation of built-up edge
2
and high sticking or welding tendency to insert / tool cutting edges.
This places Inconel 625 in the category of hard-to-machine materials. In
addition, during machining large fraction of cutting energy transforms
into heat, which stays in the tool–workpiece interface for a long time
due to low heat transfer rate of Inconel 625. The heat generation
produces high localized temperature in the cutting zone which causes
tool material softening and thus rapid tool-wear. This usually leads to
shorter tool life and deteriorated machined surface integrity.
becomes necessary. Most of the conventional cutting fluids contain
unsafe chemical constituents which may cause environmental pollution,
biological problems to worker, contamination of soil and water pollution
3,4
during its disposal. Moreover, cutting fluids account for nearly 17%
5,6
of the manufacturing cost while the tooling cost is only 8%. In the
recent past many attempts have been made to minimize the application
7
of cutting fluids to make machining operations environment friendly.
One of best machining alternative to achieve green manufacturing is
dry cutting i.e. without the use of any cutting fluid. But during dry
machining of high nickel-chromium alloys like Inconel; work material
tends to bond strongly with cutting tool surface and thus sometimes
results in premature tool failure and poor machined surface finish. In
addition, high mechanical strength combined with poor thermal
conductivity of Inconel produces unfavourable residual tensile stresses,
surface irregularities and overheating / burning in the cutting zone while
8
machining without coolant. Furthermore, dry cutting demands special
cutting tool materials like ceramic, PCD, PCBN etc. and prudent design

© KSPE and Springer 2018

 1690 / NOVEMBER 2018
6
of tool geometry and special coatings. So, conventionally these sticky
alloys are machined under flood coolant conditions to facilitate heat
transfer from chip-tool interface, which involve high machining cost,
9
worker health hazards and serious environmental issues. Moreover, at
high cutting speeds, conventional cutting fluids fail to penetrate in the
4,10
cutting zone exhibit poor machining performance. In such cases,
machining with minimum quantity lubrication (MQL) or micro
lubrication technique has been gaining attention world-wide to address
machining problems of Inconel and other alloys, mainly arising from
11
the usage of cutting fluids. In MQL machining, very small quantity of
cutting fluid (in ml/h instead of l/min.) in the form of mist or high
velocity jet is used to provide lubrication between cutting tool-workpiece
12
interface with compressed air. In the last few years, various researchers
have claimed improvement in cutting performance with MQL machining
compared to dry and conventional (flood) cooling conditions. Gupta and
13
Sood in their study witnessed drastic reduction in cutting forces, surface
roughness and tool wear by 4.08%, 7.79% and 10.03%, respectively
while MQL machining of Inconel 800 compared to flood machining
14
conditions. Dhar et al. also experienced 5-15% lesser cutting forces
and better surface finish during machining of AISI 1040 steel under
MQL as compared to dry cutting. These improvements are indicative
of effective cooling and lubrication provided by better penetration of
9 27
MQL jet/mist in the cutting zone. Similarly, Thakur et al. investigated
superior surface quality due to less abrasion and adhesive wear during
MQL turning of Inconel 718. Chip segmentation caused by high
pressure MQL jet further results in high quality machined surfaces as
15 11
reported by Ezugwu et al. Kamata and Obikawa evaluated cutting
performance of coated carbide tools under different machining
environments. It was concluded that MQL turning of Inconel 718 with
TiN/AlN coated carbide tool gives better tool life. Various previous
studies have also experienced better machining performance under
16-18
MQL turning of AISI 1045 steel, 6061 Al alloy and AISI 4140 steel.
7
Davim et al. revealed an interesting fact that 200 ml/hr MQL and flood
machining conditions produced similar surface roughness and chip form
during turning of brass. They claimed that MQL can replace flood
conditions successfully under machining conditions used in the
investigation.
More recently, nanoparticles such as CNT (carbon nanotube), C , 60
TiO , Al O , MoS etc. based nano-cutting fluids and biodegradable
2 2 3 2
vegetable oil based lubricants are introduced with MQL machining
system. Since the cutting zone temperature is quiet high in difficult-to-
cut materials, adequate cooling is also required along with lubrication
to improve cutting insert life and machined surface quality. To attain this,
nano-sized particles (1-100 nm) having high thermal conductivity and
advanced tribological characteristics are reinforced with the base cutting
19
fluid and thus enhancing MQL machining performance. Carbon
nanotube (CNT) based nano-fluids are of huge interest in MQL
machining because CNT has high heat conductivity in comparison with
20
other nanoparicles. CNT: allotrope of carbon having cylindrical
nanostructure, available as either SWCNT (single-walled carbon
nanotube) with only one graphene layer or MWCNT (multi-walled
carbon nanotube) consisting multiple rolled layers of graphene.
MWCNT can gain more chemical and thermal stability from their
inter-wall interactions compared to SWCNT whose physical properties
21
are very sensitive. Few researchers have explored the suitability of
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11
nano-fluids and vegetable oils - based cutting fluids in metal cutting
22
operations. Khandekar et al. revealed reduction of cutting force by
50% and 30% with Al O nanoparticles based nano-cutting fluid during
2 3
machining of AISI-4340 steel as compared to dry and conventional
flood machining, respectively. In addition, reduction of 54.5% and 28.5%
in surface roughness (R ) has also been reported with nano-cutting fluid.
a
23
Amrita et al. assessed performance of nano-cutting fluid using nano-
graphite particles under MQL turning of AISI 1040 steel and observed
excellent improvement in machining performance with nano-fluid MQL
24
compared to flood coolant conditions. Uysal et al. examined that MQL
machining of AISI 420 martensitic stainless steel using MoS 2
nanoparticles based cutting fluid results in minimum surface roughness
and tool wear because of improved lubrication effect with the addition
of nanoparticles. Similar outcomes have also been reported by Sahu et
20
al. in machining of titanium alloy using MWCNT based nano-fluid.
25
Hegab et al. compared MQL machining performance of Inconel 718
with different nano cutting fluids. It was revealed that MWCNT
provides higher ability of heat dissipation than Al O based nano-fluids.
2 3
26
Su et al. investigated that vegetable oil - nanographite based cutting
fluid shows better MQL performance in reducing cutting force and
cutting zone temperature compared to ester based oil. The superiority
of MQL with vegetable oil-cutting fluid over dry and wet machining of
AISI 9310 and AISI 4340 steel has also been reported by Khan et al.
28
and Lawal et al., respectively.
Literature review has illustrated that most of the MQL based
machining research work pertains to machining of Ni-Cr alloys like
Inconel 718, Inconel 800, hardened steel alloys viz. AISI 1040, AISI
4140, AISI 4340, AISI 1045, AISI 9310, brass, titanium alloys and 6061
7,9,11,13,15-18,23,27,28
Al alloy etc. However, no literature is available on MQL
machining of Ni-Cr based aerospace alloy Inconel 625 using nano
cutting fluids. Therefore, present experimental study has attempted to
explore the machining performance of nano-fluid minimum quantity
lubrication (NMQL) turning of Inconel 625 using food grade vegetable
oil-based cutting fluid reinforced with multi-walled carbon nanotubes
(MWCNT) for safe and environment friendly machining. Response
surface methodology (RSM) design approach and ANOVA test have
been utilized to arrive at optimum turning parameters which minimizing
tool flank wear (VB) and surface roughness (R ). Comparison of turning
a
performance under different cutting environments viz. dry, wet (flood)
and NMQL machining has also been made.
2. Experimental Details
2.1 Work piece and cutting tool material
Turning experiments were performed on a high-rigidity HMT-stallion-
100 HS CNC (Computer Numerical Control) lathe having 8-station
servo tool turret with specifications as: maximum spindle speed, 4000
rpm; main drive power, 5.5 kW; maximum turning diameter and length,
250mm and 460mm with Siemens 802D control system. Commercially
available Inconel 625 bar (Ø 55 mm and length 127 mm) was used as
workpiece material for machining. Chemical composition of Inconel
625 is: Cr-20.64%, Mo-8.121%, Co-0.817%, (Nb + Ta)-3.630%, Al-
0.160%, Ti-0.21%, C-0.068%, Fe-4.30%, Mn-0.318%, Si-0.211%, P-
0.011%, S-0.009% and Ni-Balance. Cutting inserts used for turning
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11
were PVD coated carbide: (Al, Ti) N (Make: Mitsubishi, Japan; Grade:
VP10RT; ISO designation: TNMG 160412-MJ). The tool holder (Widia-
MTJNL 2020 M16) and cutting insert on clamping, gave approach angle
= 93°, clearance angle = 6°, rake angle = -6° and nose radius = 1.2 mm.
2.2 Multiwall carbon nanotube (MWCNT) enhanced lubricant
Base cutting fluid / lubricant used in the study was soybean oil which
does not pose any health hazards to machine operator and is environment
friendly, biodegradable and has high viscosity index (viscosity and
o
density at 25 C: 48.0 cP and 0.917 g/ml). To enhance its thermal
conductivity and mechanical stability, hydroxyl functionalized multiwall
carbon nanotubes (MWCNT; average diameter = 10-15 nm, average
length = 1-5 μm and thermal conductivity = ~3000 W/m.k) were added
in concentrations of 0.5%, 0.75%, 1%, 1.25% and 1.5% (by weight) to
the soybean oil. In order to check the suspension stability in terms of
optimum wt.% of MWCNT in soybean oil and to achieve a stable
colloidal suspension, different mixture were put into glass flasks after
ultra-sonication using ultrasonic vibrator for 1 hour (100W, 40 kHz) and
magnetically stirred for about 30 minutes. It was found that nanoparticles
with 0.5, 0.75, 1.25 and 1.5 wt.% segregated only within 24 hours.
However, the particles with 1 wt% showed suspension stability in 72
hours. Pilot experiments were also conducted to compare the
performance of nano-fluid MQL prepared by different wt.% of MWCNT
with pure MQL. The results indicated minimum tool flank wear (150
μm) with 1% concentration of nanoparticles compared to 0.5%, 0.75%,
1.25%, 1.5% and pure MQL. Based on the findings of pilot study, it was
decided to conduct final experimentation under nano-fluid MQL with
1% weight concentration of nanoparicles in soybean oil.
2.3 NMQL (Nano-fluid MQL) system
NMQL system (Fig. 1; Make: NOGA, Israel; Model: MC3100) used
in this study, works on the principle of venturi to draw and push / target
a mixture of soybean oil and nanoparticles on tool-chip interface using
compressed air pressure of 6 bar. The nanoparticles enhanced soybean
oil rises up from the oil container / jar through NMQL supply line due
to partial vacuum that is created around the NMQL nozzle by compressed
air. The air / nanoparticles enhanced soybean oil mixture is supplied
accurately at the chip-tool interface in the form of high velocity NMQL
jet through NMQL nozzle. Flexible hose and strong magnetic base of
NMQL system allows the NMQL nozzle to be placed vertically above
at a distance of about 20 mm from the cutting tool edge during entire
turning operation. NMQL jet provides a flow rate of 75 ml/h mainly to
target rake and flank face of cutting insert to enhance its tool life and
machined surface finish.
2.4 Experimental design and procedure
In the current investigation, sequential experimental design strategy
was applied. In the first phase, two-level factorial (2k) design was used
with three identified input process parameters (k = 3) viz. cutting speed
(A), feed rate (B) and depth of cut (C) along with three additional centre
points for checking any experimental error. The range of parameters was
finalized based on review of literature, as per recommendations of tool
manufacturer for the selected work material (Inconel 625) and based on
1,3,9,11,29
the results of preliminary experiments. After analysis results of
first phase experimentation, the factorial design was augmented for
NOVEMBER 2018 / 1691
Fig. 1 Experimental set-up
additional experiments. For the second phase, central composite design
(CCD) was utilized including six axial points (2k; coded level + α) and
two centre points (coded level 0). The value of α was kept 1.68 to make
central composite design as rotatable. Total 19 experiments were
conducted at 5-levels (Table 1) and observations made for two response
factors i.e., tool flank wear (VB) and surface roughness (R ). Results
a
were statistically analysed through RSM and ANOVA to obtain optimised
machining parameters under NMQL conditions.
Fresh cutting edge of insert was used to conduct each experiment.
Toolmakers microscope (Make: Metzer, India; magnification range:
X30-X150; resolution: 5 µm) was used to measure tool flank wear (VB)
of the worn out cutting tools during experimentation. Surface roughness
(R ) was examined with a SurfTest-SJ-201 analyzer (Make: Mitutoyo,
a
Japan; cut-off length: 0.8 mm). Wear characterization was done through
SEM/ EDAX analysis of worn out inserts (SEM make: JEOL, Japan;
Model: JSM-6510LV). CCD experimental layout along with results
obtained for response factors is given in Table 2.
3. Data analysis and Discussion
Response factor models (VB and R ) were generated and evaluated
a
for input cutting parameters (A, B and C) through RSM. Quadratic
models were observed as best fit models for both responses, whereas
cubic models were aliased. Statistical significance of fitted models and
input machining parameters was investigated by using ANOVA. It was
2 2 2
observed that: B, AC, A , B , C are the statistically significant
2
parameters for VB, whereas model terms A, B, C, B are significant for
R . Model statistics reflect the value of C.V. (coefficient of variation) is
a
2
quite low i.e. less than 10% and R (coefficient of correlation) value is
greater than 0.85 for both models which indicates good signal about the
model accuracy and reliability associated with the conducted
2
experiments. Adjusted and predicted R values for VB and R were a
found in well close relation, which further validates about the fitness of
generated models. For ANOVA results and empirical model equations
of VB and R , refer supplementary file “ESM_1.pdf”.
a
 1692 / NOVEMBER 2018 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11

Table 1 Machining parameters and their levels

Levels
Parameters
-α (lowest axial) -1 (low) 0 (centre) +1 (high) +α (highest axial)
Cutting speed: A (m/min.) 16.48 25 37.5 50 58.52
Feed rate: B (mm/rev.) 0.05 0.07 0.1 0.13 0.15
Depth of cut: C (mm) 0.13 0.2 0.3 0.4 0.47

Table 2 CCD experimental layout with results

Cutting speed: A Feed rate: B Depth of cut: C Flank wear: VB Surface roughness:
Run
(m/min.) (mm/rev.) (mm) (µm) Ra (µm)
1 37.5 0.1 0.3 150 0.59
2 50 0.13 0.4 170 0.7
3 37.5 0.1 0.3 110 0.63
4 25 0.13 0.4 130 0.78
5 25 0.07 0.2 180 0.55
6 25 0.13 0.2 160 0.59
7 50 0.07 0.4 210 0.44
8 50 0.13 0.2 150 0.5
9 37.5 0.1 0.3 120 0.58
10 50 0.07 0.2 160 0.43
11 25 0.07 0.4 180 0.64
12 16.48 0.1 0.3 160 0.82
13 58.52 0.1 0.3 190 0.52
14 37.5 0.05 0.3 200 0.81
15 37.5 0.15 0.3 180 0.95
16 37.5 0.1 0.13 90 0.48
17 37.5 0.1 0.47 190 0.75
18 37.5 0.1 0.3 140 0.62
19 37.5 0.1 0.3 140 0.6

Fig. 2 Effect of machining parameters on VB

3.1 Influence of input machining parameters on tool wear (VB)

and surface roughness (Ra)
In case of tool flank wear, feed rate (B) and cutting speed-depth of
cut interaction (AC) were observed as statistical significant model
parameters. There is minimal variation in tool wear (VB) with change
of cutting speed. However, tool wear varies slightly with feed rate as Fig. 3 SEM images and EDAX analysis of worn out cutting insert
is clear from Fig. 2(a). Tool wear initially decreases to some extent with
increase in cutting speed at all feed rate range reaching minimum at
37.5 m/min., and increases slightly thereafter with increase in cutting protective covering. SEM-EDAX analysis of transferred material and
speed. Similar behavior of tool wear has been observed for change in adhered layer in Figs. 3(c) and 3(d) clearly shows elements from
feed rate. The decrease in tool wear initially with increase in cutting workpiece material such as Cr (20.84%), Ni (58.8%) and Mo (8.3%).
speed as well as feed rate is attributed to adhering of workpiece-chip With increase in feed rate/cutting speed beyond middle value, cutting
material on tool flank face as depicted in SEM images of worn out conditions become more aggressive resulting in high cutting zone
cutting insert for run no. 9 (Figs. 3(a) and 3(b)), thus providing a temperature and softening of adhered layer, which gets detached from
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11
Fig. 4 Effect of machining parameters on R a
the tool surface as revealed in SEM image of worn out cutting insert
for run no. 2, Fig. 3(e); consequently exposing the tool edge to
accelerated tool wear. Increased tool wear at higher feed rate / cutting
30
speed is reported in Fig. 2(a). Xue and Chen also experienced adhered
material deposited on tool surface, undergo a periodic sequence of
“forming - piling up – plucking off” with change in machining
parameters and tool wear changed accordingly during turning of nickel-
based alloy GH4169. Similar effect of feed rate and cutting speed on
1 13
tool wear was observed by Colak and Gupta and Sood while
machining of Inconel 718 under high pressure cooling conditions and
MQL machining of Inconel 800, respectively. Their studies revealed
that maximum tool wear occurred corresponding to upper values of
cutting speed and feed rate.
Tool wear varies slightly (decreasing initially, reaching minimum and
increasing thereafter) with change in depth of cut and at low to moderate
cutting speed range. However, tool wear rises sharply with increase in
depth of cut beyond 0.3 mm and higher cutting speed range as depicts
in Fig. 2(b). This is due to fact that more energy and cutting force is
required to remove material at higher depth of cut and higher cutting
speed. Highest tool wear is reported corresponding to maximum cutting
31
speed – depth of cut combination. Jahanbakhsh et al. noticed similar
effect of speed and depth of cut on VB (tool wear) in their experimental
investigation for optimal tool wear in machining of Inconel 625.
Fig. 4(a) describes the feed rate - cutting speed effect on surface
roughness (R ) At low level of feed rate i.e., 0.07 mm/rev., surface
a .
roughness decreases with increase in cutting speed from 25 m/min. - 50
m/min. However, at high level of feed rate (0.13 mm/rev.), surface
roughness remains nearly constant upto 31.25 m/min. and then decrease
slightly with further increase in cutting speed. The slope of R variation
a During turning of difficult-to-machine alloys like Inconel, large
with change in feed rate is steeper at higher cutting speed compared to
low speed range. This reflect surface roughness decreases significantly
with change in feed rate from 0.13 mm/rev. to 0.07 mm/rev. at higher
cutting speed compared to lower speed range. Best surface finish is
observed at lowest feed rate and highest cutting speed. Similar conditions
9
for best machined surface quality were also reported by Thakur et al.
in MQL turning of Inconel 718. Fig. 4(b) reveals the influence of
cutting speed and depth of cut on R (surface roughness). At all cutting
a Fig. 5) because of high temperature and poor rate of heat dispersion from
speed range, value of R decreases almost linearly with decrease in
a the cutting zone. Cutting conditions without coolant promotes aggressive
depth of cut. This is due to fact that at low depth of cut, lesser amount
of cutting force is required which leads to better surface finish as also
32
investigated by Amini et al. during high speed turning of Inconel 718.
Lowest value of surface roughness has been attained by high cutting
NOVEMBER 2018 / 1693
Fig. 5 Tool wear and surface roughness under dry, wet (flood) and
NMQL conditions
speed with low depth of cut as shown in Fig. 4(b).
3.2 Optimization of machining parameters under NMQL
Desirability function multi-objective optimization was applied to
optimize machining parameters for minimizing tool wear (VB) and
surface roughness (R ). The optimum values of cutting parameters have
a
been found as: cutting speed (A = 45.52 m/min.), feed rate (B = 0.1
mm/rev.) and depth of cut (C = 0.2 mm) with predicted optimum value
of VB = 141.77 µm and R = 0.47 µm at desirability level of 0.798.
a
Confirmation experiments conducted under NMQL conditions at
optimized machining parameters gave 3.34% error from predicted
value for VB and 4.67% error from predicted value of R , indicating
a
good accuracy of fitted models.
3.3 Comparison of turning performance under dry, wet (flood)
coolant and NMQL conditions
Turning experiments were conducted at recommended optimized
levels to compare machining performance under various conditions viz.
dry, wet (flood) and NMQL. Each experiment was replicated thrice to
ascertain experimental errors. Fig. 5 indicates average measured values
of VB and R under different cutting environments. Actual view of
a
experimental set up during turning operation under different cutting
conditions is shown in Fig. 6(a).
3.3.1 Tool wear
amount of heat is produced that affects tool life, machined surface
quality, cutting forces, chip form and its colour. It is known that
maximum heat generation occurs at chip-cutting tool interface, causes
rapid tool failure due to diffusion, adhesion or abrasion wear modes.
The precise penetration of coolant/lubricant is important to reduce
temperature of cutting zone to achieve lower tool wear.
Under dry cutting, maximum flank wear was observed (173.33 µm;
diffusion and plastic deformation between tool-chip interface. This leads
to softening of tool material and separation of hard binder particles of
tool coating material, which in turn decreases tool wear resistance and
produce multiple chipping and abrasion marks on tool flank face as
 1694 / NOVEMBER 2018
Fig. 6 Comparison of turning performance under different machining
conditions
found in SEM micrograph of worn out insert under dry machining, Fig.
6(c). Huge adhesive wear was also observed in dry machining due to
sticky nature and adhesive affinity of Inconel 625 and coated carbide
tool material. Similar wear phenomenon was reported by previous
27, 33
studies during dry machining of AISI 9310 alloy steel and titanium
alloys (Ti-6Al-4V).
Under wet (flood) conditions (coolant used: Fuchs lubricants-
ECOCOOL 600 NBF-C at flow rate: 8 l/min.,0.5 bar), although bulk
supply of coolant is available but, it is unable to penetrate in the plastic
4,8
zone of tool-chip interface, exposed to highest temperature. Segregated
adhesion and burning of chip material was noticed along with built up
edge (BUE) formation under flood cutting conditions, Fig. 6(c). The
wear observed was less as compared to dry condition due to lubrication
ability of coolant used in wet (flood) machining of Inconel 625.
Minimum tool wear (146.67 µm; Fig. 5) was examined under
NMQL machining conditions. This is due to fact that high velocity
NMQL jet along with compressed air approaches deeper and closer to
cutting tool edge-chip interface, which leads to adequate reduction of
4
cutting zone temperature compared to flood machining conditions. In
NMQL condition, cutting edge of insert is protected by the layer of
33
lubricating film adhered to tool flank face resulting uniform flank
wear as revealed from SEM-wear characterization of worn out cutting
edge under NMQL machining of Inconel 625, Fig. 6(c). In addition,
suspended MWCNT nanoparticles having cylindrical shape provides
roll-bearing effect at nano-scale during entrapment of nano cutting fluid
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11
in chip-tool interface and thus results in lower frictional forces,
enhancement of tool wear resistance and tribological characteristics at
34,35
higher temperature.
Furthermore, addition of MWCNT nanoparticles to the base oil
accelerates the heat transfer rate from the tool-workpiece-chip interface
19
because of their high thermal conductivity. Due to better lubricating
and cooling action of NMQL, tool material retains its strength for longer
time and hence provides maximum tool life compared to other two
methods. Improvement of tool life with MWCNT nano cutting fluid in
machining of titanium alloys and under MQL machining of Inconel 718
9,20
was also confirmed by earlier investigators. Tool wear is reduced by
18.17% and 4.54% under NMQL turning of Inconel 625 compared to
dry machining and wet (flood) cutting conditions, respectively.
3.3.2 Chip form and colour
Chip form and colour were examined under dry, wet (flood) and
NMQL cutting conditions as depicted in Fig. 6(b). Machining of Inconel
625 under dry condition produced short helical chips, whereas in wet
(flood) machining long helical continuous chips were formed. Small
spiral form of chips were observed during NMQL machining due to chip
segmentation caused by high-velocity NMQL jet, resulting in better
25
surface finish. Similar chip forms were also noticed by Gupta and
13
Sood during machining of Inconel 800 and titanium alloy under flood
and MQL conditions. The colour of chips under dry condition was burnt
blue which indicates high temperature in the cutting zone due to absence
of coolant. Similarly, chips of light blue colour observed during wet
machining shows about the ineffectiveness of bulk coolant in removal
of heat from the tool-chip interface during machining. However, grey
colour chips were viewed under NMQL condition due to reduction of
cutting zone temperature. Similar chip colours were confirmed by
23
previous investigator in NMQL turning of AISI 1040 steel with nano-
graphite based cutting fluid and claimed better cooling effect at chip-
tool interface with nano-fluids as compared to conventional cutting
fluids.
3.3.3 Machined surface quality
Maximum surface roughness (0.767 μm; Fig. 5) was observed during
dry machining of Inconel 625 because of aggressive cutting conditions
at high temperature in absence of coolant, results in higher tool wear
rate and poor machined surface quality. Under conventional flood
conditions, lower surface roughness (R ) was noticed compared to dry
a
condition due to lubrication ability of coolant used in wet (flood)
machining. However, minimum surface roughness (0.493 μm; Fig. 5)
was reported under NMQL machining conditions due to improved
lubrication and better heat dissipation at rake and flank face provided
by nano cutting fluid as compared to conventional cutting fluid. In
addition, flank wear under NMQL machining is more evenly distributed,
as revealed from SEM micrograph shown in Fig. 6(c), thereby improving
surface finish. Similar variations in surface roughness were investigated
22 25
by Khandekar et al. and Hegab et al. while machining of AISI 4340
alloy steel and Inconel 718 using nano-fluid with Al O and MWCNT
2 3
nanoparticles, respectively. Surface finish of Inconel 625 under NMQL
turning is improved by 55.58% compared to dry machining and 5.48%
compared to conventional flood cutting conditions.
 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11
4. Conclusions
In this study, machinability of Inconel 625 using coated carbide
insert tool has been experimentally investigated under NMQL turning.
Comparison of machining performance under different cutting
environments has also been explored at selected optimum turning
parameters. The following conclusions are drawn from the present
experimental study:
1. Statistical analysis of data reveals feed rate (B) and cutting speed-
depth of cut (AC) interaction as leading factors affecting tool flank
wear, whereas all the factors viz. cutting speed (A), feed rate (B)
and depth of cut (C) are found significant for surface roughness.
2. Optimised turning parameters for Inconel 625 under NMQL
condition are found as: cutting speed = 45.52 m/min., feed rate =
0.1 mm/rev., depth of cut = 0.2 mm and 1% (wt.) concentration
of multiwall CNT nanoparticles with measured tool flank wear
(VB) = 146.67 µm and surface roughness (Ra) = 0.493 µm.
3. SEM-wear characterization reveals chipping, abrasion and
adhesive are main wear modes in dry cutting of Inconel 625.
Under flood coolant conditions, adhesive wear along with BUE is
prominent, whereas NMQL results in uniform flank wear across
the tool cutting edge.
4. Tool wear is reduced by 18.17% and 4.54% under NMQL turning
of Inconel 625 compared to dry machining and wet (flood) cutting
conditions, respectively.
5. Surface finish of Inconel 625 under NMQL turning is improved
by 55.58% and 5.48% compared to dry cutting and conventional
flood machining, respectively.
6. The results indicate that NMQL technique can be a better
alternative for sustainable manufacturing, particularly hard-to-
machine materials like Inconel 625, by enhancing tool life and
surface finish. Moreover, NMQL provides environment friendly
machining by maintaining neat, clean, healthy, pollution free and
dry working area.
REFERENCES
1. Çolak, O., “Investigation on Machining Performance of Inconel 718
in High Pressure Cooling Conditions,” Strojniški vestnik-Journal of
Mechanical Engineering, Vol. 58, No. 11, pp. 683-690, 2012.
2. Senthilkumaar, J., Selvarani, P., and Arunachalam, R., “Intelligent
Optimization and Selection of Machining Parameters in Finish
Turning and Facing of Inconel 718,” The International Journal of
Advanced Manufacturing Technology, Vol. 58, Nos. 9-12, pp. 885-
894, 2012.
3. Thakur, D. G., Ramamoorthy, B., and Vijayaraghavan, L.,
“Investigation and Optimization of Lubrication Parameters in High
Speed Turning of Superalloy Inconel 718,” The International Journal
of Advanced Manufacturing Technology, Vol. 50, Nos. 5-8, pp. 471-
478, 2010.
4. Dhar, N. R., Kamruzzaman, M., and Ahmed, M., “Effect of Minimum
Quantity Lubrication (MQL) on Tool Wear and Surface Roughness
NOVEMBER 2018 / 1695
in Turning AISI-4340 Steel,” Journal of Materials Processing
Technology, Vol. 172, No. 2, pp. 299-304, 2006.
5. Sharma, A. K., Tiwari, A. K., and Dixit, A. R., “Effects of Minimum
Quantity Lubrication (MQL) in Machining Processes Using
Conventional and Nanofluid Based Cutting Fluids: A Comprehensive
Review,” Journal of Cleaner Production, Vol. 127, pp. 1-18, 2016.
6. Singh, T., Singh, P., Dureja, J. S., Dogra, M., Singh, H., and Bhatti,
M. S., “A Review of Near Dry Machining/Minimum Quantity
Lubrication Machining of Difficult to Machine Alloys,” International
Journal of Machining and Machinability of Materials, Vol. 18, No.
3, pp. 213-251, 2016.
7. Davim, J. P., Sreejith, P., and Silva, J., “Turning of Brasses Using
Minimum Quantity of Lubricant (MQL) and Flooded Lubricant
Conditions,” Materials and Manufacturing Processes, Vol. 22, No. 1,
pp. 45-50, 2007.
8. Devillez, A., Le Coz, G., Dominiak, S., and Dudzinski, D., “Dry
Machining of Inconel 718, Workpiece Surface Integrity,” Journal of
Materials Processing Technology, Vol. 211, No. 10, pp. 1590-1598,
2011.
9. Thakur, D., Ramamoorthy, B., and Vijayaraghavan, L., “Influence of
Minimum Quantity Lubrication on the High Speed Turning of
Aerospace Material Superalloy Inconel 718,” International Journal
of Machining and Machinability of Materials, Vol. 13, Nos. 2-3, pp.
203-214, 2013.
10. Shokrani, A., Dhokia, V., and Newman, S. T., “Environmentally
Conscious Machining of Difficult-to-Machine Materials with Regard
to Cutting Fluids,” International Journal of Machine Tools and
Manufacture, Vol. 57, pp. 83-101, 2012.
11. Kamata, Y. and Obikawa, T., “High Speed MQL Finish-Turning of
Inconel 718 with Different Coated Tools,” Journal of Materials
Processing Technology, Vols. 192-193, pp. 281-286, 2007.
12. Sharma, V. S., Singh, G., and Sørby, K., “A Review on Minimum
Quantity Lubrication for Machining Processes,” Materials and
Manufacturing Processes, Vol. 30, No. 8, pp. 935-953, 2015.
13. Gupta, M. K. and Sood, P. K., “Machining Comparison of Aerospace
Materials Considering Minimum Quantity Cutting Fluid: A Clean
and Green Approach,” Proceedings of the Institution of Mechanical
Engineers, Part C: Journal of Mechanical Engineering Science, Vol.
231, No. 8, pp. 1445-1464, 2017.
14. Dhar, N., Ahmed, M., and Islam, S., “An Experimental Investigation
on Effect of Minimum Quantity Lubrication in Machining AISI 1040
Steel,” International Journal of Machine Tools and Manufacture, Vol.
47, No. 5, pp. 748-753, 2007.
15. Ezugwu, E., Bonney, J., Fadare, D., and Sales, W., “Machining of
Nickel-Base, Inconel 718, Alloy with Ceramic Tools under Finishing
Conditions with Various Coolant Supply Pressures,” Journal of
Materials Processing Technology, Vols. 162-163, pp. 609-614, 2005.
16. Frăţilă, D. and Caizar, C., “Investigation of the Influence of Process
Parameters and Cooling Method on the Surface Quality of AISI-1045
 1696 / NOVEMBER 2018 INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11

during Turning,” Materials and Manufacturing Processes, Vol. 27, No. Cleaner Production, Vol. 66, pp. 610-618, 2014.
10, pp. 1123-1128, 2012.
29. Mitsubishi Materials Corporation, “General Catalogue: C007B,”
17. Sreejith, P. S., “Machining of 6061 Aluminium Alloy with MQL, Dry http://www.mitsubishicarbide.com/application/files/6114/5698/5115/
and Flooded Lubricant Conditions,” Materials Letters, Vol. 62, No. 2, catalog_c007b_full.pdf (Accessed 25 SEP 2017)
pp. 276-278, 2008.
30. Xue, C. and Chen, W., “Adhering Layer Formation and Its Effect on
18. Hadad, M. and Sadeghi, B., “Minimum Quantity Lubrication-MQL the Wear of Coated Carbide Tools during Turning of a Nickel-Based
Turning of AISI 4140 Steel Alloy,” Journal of Cleaner Production, Alloy,” Wear, Vol. 270, Nos. 11-12, pp. 895-902, 2011.
Vol. 54, pp. 332-343, 2013.
31. Jahanbakhsh, M., Akhavan Farid, A., and Lotfi, M., “Optimal Flank
19. Srikant, R. R., Prasad, M. M. S., Amrita, M., Sitaramaraju, A. V., and Wear in Turning of Inconel 625 Super-Alloy Using Ceramic Tool,”
Krishna, P. V., “Nanofluids as a Potential Solution for Minimum Proceedings of the Institution of Mechanical Engineers, Part B:
Quantity Lubrication: A Review,” Proceedings of the Institution of Journal of Engineering Manufacture, Vol. 232, No. 2, pp. 208-216,
Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2018.
Vol. 228, No. 1, pp. 3-20, 2014.
32. Amini, S., Fatemi, M. H., and Atefi, R., “High Speed Turning of
20. Sahu, N. K., Andhare, A. B., and Raju, R. A., “Evaluation of Inconel 718 Using Ceramic and Carbide Cutting Tools,” Arabian
Performance of Nanofluid Using Multiwalled Carbon Nanotubes for Journal for Science and Engineering, Vol. 39, No. 3, pp. 2323-2330,
Machining of Ti-6Al-4V,” Machining Science and Technology, Vol. 2014.
22, No. 3, pp. 476-492, 2018.
33. Liu, Z., An, Q., Xu, J., Chen, M., and Han, S., “Wear Performance
21. Zhang, X., Zhou, W.-X., Chen, X.-K., Liu, Y.-Y., and Chen, K.-Q., of (nc-Altin)/(a-Si3N4) Coating and (nc-AlCrN)/(a-Si3N4) Coating in
“Significant Decrease in Thermal Conductivity of Multi-Walled High-Speed Machining of Titanium Alloys under Dry and Minimum
Carbon Nanotube Induced by Inter-Wall Vander Waals Interactions,” Quantity Lubrication (MQL) Conditions,” Wear, Vol. 305, Nos. 1-2,
Physics Letters A, Vol. 380, No. 21, pp. 1861-1864, 2016. pp. 249-259, 2013.

22. Khandekar, S., Sankar, M. R., Agnihotri, V., and Ramkumar, J., 34. Nam, J. S., Lee, P.-H., and Lee, S. W., “Experimental Characterization
“Nano-Cutting Fluid for Enhancement of Metal Cutting Performance,” of Micro-Drilling Process Using Nanofluid Minimum Quantity
Materials and Manufacturing Processes, Vol. 27, No. 9, pp. 963-967, Lubrication,” International Journal of Machine Tools and
2012. Manufacture, Vol. 51, Nos. 7-8, pp. 649-652, 2011.

23. Amrita, M., Srikant, R., and Sitaramaraju, A., “Performance 35. Sharma, A. K., Tiwari, A. K., Singh, R. K., and Dixit, A. R.,
Evaluation of Nanographite-Based Cutting Fluid in Machining “Tribological Investigation of TiO2 Nanoparticle Based Cutting
Process,” Materials and Manufacturing Processes, Vol. 29, No. 5, Fluid in Machining Under Minimum Quantity Lubrication (MQL),”
pp. 600-605, 2014. Materials Today: Proceedings, Vol. 3, No. 6, pp. 2155-2162, 2016.

24. Uysal, A., Demiren, F., and Altan, E., “Applying Minimum Quantity
Lubrication (MQL) Method on Milling of Martensitic Stainless Steel
by Using Nano Mos2 Reinforced Vegetable Cutting Fluid,” Procedia-
Social and Behavioral Sciences, Vol. 195, pp. 2742-2747, 2015.
Talwinder Singh
25. Hegab, H., Umer, U., Soliman, M., and Kishawy, H. A., “Effects of Ph.D. candidate in the Department of Mech-
Nano-Cutting Fluids on Tool Performance and Chip Morphology anical Engineering, Punjabi University, Pati-
during Machining Inconel 718,” The International Journal of ala-INDIA. His areas of interest are machin-
ing of aerospace alloys under minimum
Advanced Manufacturing Technology, Vol. 96, Nos. 9-12, pp. 3449-
quantity lubrication machining/near dry
3458, 2018. machining, green manufacturing and tool
wear monitoring.
26. Su, Y., Gong, L., Li, B., Liu, Z., and Chen, D., “Performance E-mail: tp_tiet@yahoo.co.in
Evaluation of Nanofluid MQL with Vegetable-Based Oil and Ester
Oil as Base Fluids in Turning,” The International Journal of Advanced
Manufacturing Technology, Vol. 83, Nos. 9-12, pp. 2083-2089, 2016. Jasminder Singh Dureja
Professor in the Department of Mechanical
27. Khan, M. M. A., Mithu, M. A. H., and Dhar, N. R., “Effects of Engineering, Punjabi University, Patiala-
Minimum Quantity Lubrication on Turning AISI 9310 Alloy Steel INDIA. His areas of interest are hard turn-
Using Vegetable Oil-Based Cutting Fluid,” Journal of Materials ing, tool wear, condition-based maintenance
and monitoring apart from statistical model-
Processing Technology, Vol. 209, Nos. 15-16, pp. 5573-5583, 2009. ling and optimisation, machining of aero-
space alloys under minimum quantity lubri-
28. Lawal, S. A., Choudhury, I. A., and Nukman, Y., “Evaluation of
cation machining/near dry machining, green
Vegetable and Mineral Oil-in-Water Emulsion Cutting Fluids in manufacturing, etc.
Turning AISI 4340 Steel with Coated Carbide Tools,” Journal of E-mail: jsdureja73@gmail.com
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING Vol. 19, No. 11 NOVEMBER 2018 / 1697

Manu Dogra
Associate Professor in the Department of
Mechanical Engineering, UIET, PUSSGRC,
Hoshiarpur-INDIA. His area of interest
includes machining, statistical modeling,
welding and MQL machining.
E-mail: mdogra7@gmail.com

Manpreet S Bhatti
Associate Professor in the Department of
Botanical and Environmental Sciences, Guru
Nanak Dev University, Amritsar-INDIA. His
areas of interest are design of experiments
(DOE), statistical modelling, artificial neural
network modelling, response surface meth-
odology and process optimization.
E-Mail: mbhatti73@gmail.com