A Multi-Objective optimization framework for the sustainable machining of Monel 400
Abstract This study explores the synergistic effects of lubrication as well as cooling on the machinability behaviour of the superalloy Monel 400. A comparative assessment was conducted across four machining environments—dry cutting, Minimum Quantity Lubrication (MQL), Cryogenic CO₂, and a hybrid MQ...
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Nature Portfolio
2025-07-01
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| Online Access: | https://doi.org/10.1038/s41598-025-01543-9 |
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| author | Binayak Sen Prasadaraju Kantheti Sachin Rathore Bhavesh Kanabar Ramachandran Thulasiram Manoj Kumar Abhijit Bhowmik A. Johnson Santhosh |
| author_facet | Binayak Sen Prasadaraju Kantheti Sachin Rathore Bhavesh Kanabar Ramachandran Thulasiram Manoj Kumar Abhijit Bhowmik A. Johnson Santhosh |
| author_sort | Binayak Sen |
| collection | DOAJ |
| description | Abstract This study explores the synergistic effects of lubrication as well as cooling on the machinability behaviour of the superalloy Monel 400. A comparative assessment was conducted across four machining environments—dry cutting, Minimum Quantity Lubrication (MQL), Cryogenic CO₂, and a hybrid MQL + CO₂ approach. Among these, MQL + CO₂ exhibited superior performance, yielding reductions of 19.58% in cutting force, 19.10% in tool wear, and 47.19% in surface roughness relative to dry cutting. Scanning Electron Microscopy (SEM) analysis identified adhesion and abrasion as the predominant wear mechanisms. Adhesion, driven by elevated cutting temperatures, facilitates material transfer between the tool and workpiece, while abrasion arises from the interaction of hard alloy particles with the tool surface, resulting in micro-scratches. Analysis of variance revealed that feed and cutting speed are the utmost influential parameters influencing machining outcomes. Utilizing Multi-Objective Response Surface Methodology, the study established optimal machining conditions—cutting speed of 78.35 m/min, feed of 0.1 mm/rev, and depth of cut of 1 mm—attaining a composite desirability of 0.84. These findings offer a sustainable framework for optimizing the machinability of Monel 400, with significant implications for aerospace and high-precision manufacturing industries. |
| format | Article |
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| institution | Kabale University |
| issn | 2045-2322 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Nature Portfolio |
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| spelling | doaj-art-ca5b368e16414b0983cda2f33097fe3d2025-08-20T04:02:56ZengNature PortfolioScientific Reports2045-23222025-07-0115111810.1038/s41598-025-01543-9A Multi-Objective optimization framework for the sustainable machining of Monel 400Binayak Sen0Prasadaraju Kantheti1Sachin Rathore2Bhavesh Kanabar3Ramachandran Thulasiram4Manoj Kumar5Abhijit Bhowmik6A. Johnson Santhosh7Centre for Computational Modeling, Chennai Institute of TechnologyDepartment of Mechanical Engineering, SRKR Engineering CollegeDepartment of Mechanical Engineering, GLA UniversityMarwadi University Research Center, Department of Mechanical Engineering, Faculty of Engineering & Technology, Marwadi UniversityDepartment of Mechanical Engineering, School of Engineering and Technology, JAIN (Deemed to be University)Department of Mechanical Engineering, ABES Engineering CollegeDepartment of Mechanical Engineering, Graphic Era (Deemed to be University)Faculty of Mechanical Engineering, Jimma Institute of Technology, Jimma UniversityAbstract This study explores the synergistic effects of lubrication as well as cooling on the machinability behaviour of the superalloy Monel 400. A comparative assessment was conducted across four machining environments—dry cutting, Minimum Quantity Lubrication (MQL), Cryogenic CO₂, and a hybrid MQL + CO₂ approach. Among these, MQL + CO₂ exhibited superior performance, yielding reductions of 19.58% in cutting force, 19.10% in tool wear, and 47.19% in surface roughness relative to dry cutting. Scanning Electron Microscopy (SEM) analysis identified adhesion and abrasion as the predominant wear mechanisms. Adhesion, driven by elevated cutting temperatures, facilitates material transfer between the tool and workpiece, while abrasion arises from the interaction of hard alloy particles with the tool surface, resulting in micro-scratches. Analysis of variance revealed that feed and cutting speed are the utmost influential parameters influencing machining outcomes. Utilizing Multi-Objective Response Surface Methodology, the study established optimal machining conditions—cutting speed of 78.35 m/min, feed of 0.1 mm/rev, and depth of cut of 1 mm—attaining a composite desirability of 0.84. These findings offer a sustainable framework for optimizing the machinability of Monel 400, with significant implications for aerospace and high-precision manufacturing industries.https://doi.org/10.1038/s41598-025-01543-9Monel-400Tool wearSurface morphologySustainable lubrication/CoolingMulti-objective optimization |
| spellingShingle | Binayak Sen Prasadaraju Kantheti Sachin Rathore Bhavesh Kanabar Ramachandran Thulasiram Manoj Kumar Abhijit Bhowmik A. Johnson Santhosh A Multi-Objective optimization framework for the sustainable machining of Monel 400 Scientific Reports Monel-400 Tool wear Surface morphology Sustainable lubrication/Cooling Multi-objective optimization |
| title | A Multi-Objective optimization framework for the sustainable machining of Monel 400 |
| title_full | A Multi-Objective optimization framework for the sustainable machining of Monel 400 |
| title_fullStr | A Multi-Objective optimization framework for the sustainable machining of Monel 400 |
| title_full_unstemmed | A Multi-Objective optimization framework for the sustainable machining of Monel 400 |
| title_short | A Multi-Objective optimization framework for the sustainable machining of Monel 400 |
| title_sort | multi objective optimization framework for the sustainable machining of monel 400 |
| topic | Monel-400 Tool wear Surface morphology Sustainable lubrication/Cooling Multi-objective optimization |
| url | https://doi.org/10.1038/s41598-025-01543-9 |
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