Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different...

Area of Science:

• Materials Science
• Manufacturing Engineering

Background:

• Machining nickel-based superalloys presents challenges like high temperatures and poor surface finish.
• Effective cooling and lubrication are crucial for managing these difficulties.

Purpose of the Study:

• To comparatively evaluate four cooling/lubrication techniques: dry, wet, minimum quantity lubricant (MQL), and compressed-air.
• To assess their impact on turning Nitronic 60 steel with SiAlON ceramic inserts.

Main Methods:

• Utilized Taguchi's L16 orthogonal array for 16 turning trials.
• Varied cutting conditions and lubrication modes.
• Analyzed machinability parameters including cutting force, temperature, surface finish, and tool life.

Main Results:

• MQL demonstrated superior performance with lower cutting forces, improved surface finish, reduced cutting temperatures, and extended tool life.
• MQL machining showed a significant increase in tool life: 11% (wet), 72% (compressed-air), and 138% (dry).
• Dry, wet, and compressed-air methods were negatively impacted by friction and burr formation, leading to increased tool wear.

Conclusions:

• MQL is highly effective for machining Nitronic 60 steel, offering better heat extraction and lubrication.
• The study highlights MQL as a promising and economical solution for challenging superalloy machining.