Enhancing Sustainable Machining of Inconel 718 via Synergistic Coupling of Rehbinder Effect and Heat Transfer Using...

Inconel 718 exhibits poor machinability due to its high strength and low thermal conductivity, which induce severe thermo-mechanical loads. Conventional cooling strategies struggle to concurrently regulate heat dissipation and interface lubrication. This paper proposes a machining method based on Active Thermal Conductive Media (ATCM), which simultaneously exerts the Rehbinder mechanochemical effect and solid-phase enhanced heat transfer effect by pre-coating a liquid graphene film on the workpiece surface. Orthogonal turning tests were conducted using a K313 carbide tool at a cutting speed of 30 m/min, cutting width of 2 mm, and undeformed chip thickness of 0.1 mm. The cutting force, cutting temperature, cutting power, and tool wear characteristics under six machining conditions-dry cutting, flood cutting, Minimum Quantity Lubrication (MQL), Cryogenic MQL (CMQL), Nanofluid MQL (NMQL), and ATCM-assisted cutting-are systematically compared. The results show that ATCM achieves a 21.6% reduction in cutting force, a 20% reduction in cutting temperature, and a 34.9% reduction in cutting power through the synergistic coupling effect of reduced heat generation and enhanced heat dissipation, with adhesive wear and diffusion wear of the cutting tool significantly suppressed.