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A Multi-Objective optimization framework for the sustainable machining of Monel 400.

Binayak Sen1,2, Prasadaraju Kantheti3, Sachin Rathore4

  • 1Centre for Computational Modeling, Chennai Institute of Technology, Chennai, 600069, Tamil Nadu, India.

Scientific Reports
|July 10, 2025
PubMed
Summary

The hybrid Minimum Quantity Lubrication (MQL) plus CO₂ method significantly improves Monel 400 machinability. This approach reduces cutting force, tool wear, and surface roughness, offering a sustainable manufacturing solution.

Keywords:
Monel-400Multi-objective optimizationSurface morphologySustainable lubrication/CoolingTool wear

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Tribology

Background:

  • Superalloys like Monel 400 present significant machining challenges due to their high strength and toughness.
  • Optimizing machining processes is crucial for industries such as aerospace and precision manufacturing to reduce costs and improve efficiency.

Purpose of the Study:

  • To investigate the combined effects of lubrication and cooling on the machinability of Monel 400.
  • To compare the performance of different machining environments: dry cutting, Minimum Quantity Lubrication (MQL), Cryogenic CO₂, and a hybrid MQL + CO₂ approach.
  • To identify optimal machining parameters for enhanced Monel 400 machinability.

Main Methods:

  • Comparative machining assessment across four environments: dry, MQL, Cryogenic CO₂, and hybrid MQL + CO₂.
  • Scanning Electron Microscopy (SEM) for analyzing tool wear mechanisms (adhesion and abrasion).
  • Analysis of Variance (ANOVA) to determine the influence of machining parameters (feed, cutting speed, depth of cut).
  • Multi-Objective Response Surface Methodology (MORSM) to establish optimal machining conditions.

Main Results:

  • The hybrid MQL + CO₂ method demonstrated superior performance, reducing cutting force by 19.58%, tool wear by 19.10%, and surface roughness by 47.19% compared to dry cutting.
  • SEM analysis confirmed adhesion and abrasion as primary wear mechanisms, influenced by temperature and hard particle interactions.
  • ANOVA indicated feed and cutting speed as the most critical parameters affecting machining outcomes.
  • Optimal conditions identified: 78.35 m/min cutting speed, 0.1 mm/rev feed, and 1 mm depth of cut, achieving a composite desirability of 0.84.

Conclusions:

  • The hybrid MQL + CO₂ machining strategy offers a sustainable and effective method for improving Monel 400 machinability.
  • Understanding wear mechanisms and optimizing parameters are key to enhancing the performance and efficiency of machining challenging superalloys.
  • The findings provide a practical framework for optimizing Monel 400 machining in demanding industrial applications.