Parametric Analysis of Tool Wear, Surface Roughness and Energy Consumption during Turning of Inconel 718 under Dry, Wet and MQL Conditions

Abstract

Economy and productivity are the two most important elements of modern manufacturing systems. Economy is associated with energy-efficient operations, which results in an overall high input-to-output ratio, while productivity is related to quality and quantity. This specific work presents experimental investigations of the use of cooling conditions (dry, MQL and wet) as input variables alongside other input parameters, including depth of cut, feed and cutting speed. This research aimed to investigate the variation in output responses including tool wear, specific cutting energy, and surface roughness while machining Inconel 718, a nickel-based super alloy. For experimentation, three levels of depth of cut, feed, and cutting speed were chosen. The Taguchi method was used for the experimental design. The contribution ratio of each input parameter was ascertained through analysis of variance (ANOVA). Use of coolant showed a positive effect on process parameters, particularly MQL. By adapting the optimum machining conditions, specific cutting energy was improved by 27%, whereas surface roughness and tool wear were improved by 15% and 30%, respectively.

Keywords

• Inconel 718
• Taguchi experimental design
• MQL
• green processing methods
• sustainable manufacturing
• process optimization for waste reduction