Sustainability assessment of cutting fluids for flooded approach through a comparative surface integrity evaluation of I
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ORIGINAL ARTICLE
Sustainability assessment of cutting fluids for flooded approach through a comparative surface integrity evaluation of IN718 Sadaf Zahoor 1,2 & Walid Abdul-Kader 1 & Kashif Ishfaq 2 Received: 1 July 2020 / Accepted: 21 September 2020 / Published online: 28 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract The surface integrity (SI) of IN718 is affected by the excessive heat generation during the machining operation. While milling of Ni-based superalloys, use of traditional flooded strategy is encouraged though, due to its superior heat dissipating capacity. However, the cutting lubricants that have been conventionally employed during this approach are subjected to several concerns in regard to sustainability. Instead, vegetable ester-based biodegradable oil, as eco-friendly cutting oil, is one of the suggested choices formerly employed with minimum quantity lubrication (MQL). Therefore, this experimental investigation tries to combine the advantages of flooded cooling method with sustainable cutting fluid to review its impact on the SI of IN718 at first. It then focuses on establishing a comparison with conventional wet and dry approaches to characterize the machinability and the SI. The milling was carried out under the 450 Mecagreen vegetable ester-based biodegradable oil-assisted flooded condition, the Hocut WS8065 mineral oil-assisted flooded condition, and the dry condition. The three process variables, cutting speed (νc), feed per flute (ƒz), and axial depth of cut (ap) were considered for all the three environments. The SI characteristics such as surface roughness (SR), surface topography, microhardness, microstructural alterations, white layer formation, grain refinement, and residual stresses were considered as the response variables. The experimental exploration is complemented with scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction analysis (XRD). Keywords IN718 . Cooling strategies . Surface integrity . Vegetable ester-based biodegradable oil . Milling process . SEM . EDS . XRD
1 Introduction The rapid increasing demand of precision manufacturing in aerospace and bioimplant applications necessitates improvement of the machining processes for better surface integrity (SI). The SI of the machined components influences their inservice performance; therefore, inferior SI may lead to component failure. Failure investigations in these sectors reveal that the majority of catastrophes occurred due to the poor SI [1]. The surface integrity mainly relates to the three different attributes of a machined part, i.e., (i) surface texture (surface roughness and * Sadaf Zahoor [email protected] Walid Abdul-Kader [email protected] 1
University of Windsor, Windsor, Ontario, Canada
2
University of Engineering and Technology, Lahore, Pakistan
surface topography), (ii) subsurface metallurgical layer (microhardness and microstructure), and (iii) residual stresses. Ni-based superalloy IN718 is the best candidate material for t
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