A new approach of measurement and analysis of PVD - TiAlN coated carbide tools in machining of Monel 400 alloy under hybrid cooling conditions

Abstract

This research work focuses on the efficacy of minimum quantity lubrication (MQL) and cryogenic carbon dioxide (CO2) cooling in high-speed machining of nickel-based alloys. CO2 and MQL supplied in the rake face were compared to CO2 and MQL in Monel 400 turning. Tool wear, temperature, surface roughness, and microstructural assessments were done to compute the cooling influence of distinct approaches. Energy dispersive spectrometry (EDS) mapping is employed to investigate the abrasion and adhesion mechanisms. The wear levels were reduced under the use of the hybrid approach; the decrease in flank value value relative to the hybrid condition is 78%, 36%, and 27%, respectively. In terms of crater wear, the reduction was 78%, 54%, and 48% over dry, MQL, and cryo CO2, respectively. Findings have portrayed that the lessening of temperature at the cutting area with the hybrid condition reduces the roughness by 58%, 44%, and 20% over dry, MQL, and cryo CO2. Moreover, verdicts of the investigation confirm smaller grain size and high hardness under cryo cooling condition.