Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718
Aero-engine components are subjected to extreme service conditions, requiring high-quality holes, extended tool life, and sustainable operations during machining. This study investigates the helical milling of Inconel 718 using a hybrid cryogenic and minimal quantity lubrication (MQL) lubri-cooling...
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Elsevier
2025-06-01
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| Series: | Results in Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2590123025008539 |
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| author | Robson Bruno Dutra Pereira Gaizka Gómez-Escudero Amaia Calleja-Ochoa Octavio Pereira Haizea González-Barrio Lincoln Cardoso Brandão Luis Norberto López de Lacalle |
| author_facet | Robson Bruno Dutra Pereira Gaizka Gómez-Escudero Amaia Calleja-Ochoa Octavio Pereira Haizea González-Barrio Lincoln Cardoso Brandão Luis Norberto López de Lacalle |
| author_sort | Robson Bruno Dutra Pereira |
| collection | DOAJ |
| description | Aero-engine components are subjected to extreme service conditions, requiring high-quality holes, extended tool life, and sustainable operations during machining. This study investigates the helical milling of Inconel 718 using a hybrid cryogenic and minimal quantity lubrication (MQL) lubri-cooling strategy. The performance of this method is compared to conventional flood coolant and MQL strategies in terms of tool life, cutting forces, hole quality, and wear mechanisms. The cryogenic/MQL lubri-cooling approach achieved the longest tool life, followed by flood coolant and MQL, producing 20% more holes than in the coolant case and 71.43% more holes than in the MQL case. Roughness results obtained in the last hole machined under the cryo-MQL environment outperformed those of the last hole machined under the coolant and MQL environments by 12.76% and 16%, respectively. However, the cryogenic/MQL strategy exhibited the highest cutting forces, possibly due to material embrittlement caused by the low-temperature environment. The MQL strategy resulted in the shortest tool life, attributed to severe chip adhesion caused by the low lubrication flow rate. Adhesion was identified as the primary wear mechanism, with additional evidence of abrasion, and built-up edges. Nonparametric Friedman rank-sum and Wilcoxon tests revealed statistically significant differences among all lubri-cooling conditions for the first seven holes. The cryogenic/MQL strategy demonstrated the lowest wear, followed by flood coolant and MQL. |
| format | Article |
| id | doaj-art-d389206a751f48bfbc8e38208cd9eea7 |
| institution | DOAJ |
| issn | 2590-1230 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Results in Engineering |
| spelling | doaj-art-d389206a751f48bfbc8e38208cd9eea72025-08-20T03:06:05ZengElsevierResults in Engineering2590-12302025-06-012610477610.1016/j.rineng.2025.104776Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718Robson Bruno Dutra Pereira0Gaizka Gómez-Escudero1Amaia Calleja-Ochoa2Octavio Pereira3Haizea González-Barrio4Lincoln Cardoso Brandão5Luis Norberto López de Lacalle6Center for Innovation in Modelling and Optimization of Systems - CIMOS, Center for Innovation in Sustainable Manufacturing - CIMS, Department of Mechanical and Industrial Engineering, Federal University of São João del-Rei (UFSJ), Frei Orlando Square, São João del-Rei, 36307-352, MG, Brazil; Department of Mechanical Engineering, Faculty of Engineering of Bilbao, Basque Country University (UPV/EHU), Alameda de Urquijo, Bilbao, 48013, Biscay, Spain; Corresponding author at: Center for Innovation in Modelling and Optimization of Systems - CIMOS, Center for Innovation in Sustainable Manufacturing - CIMS, Department of Mechanical and Industrial Engineering, Federal University of São João del-Rei (UFSJ), Frei Orlando Square, São João del-Rei, 36307-352, MG, Brazil.Department of Mechanical Engineering, Faculty of Engineering of Bilbao, Basque Country University (UPV/EHU), Alameda de Urquijo, Bilbao, 48013, Biscay, Spain; Aeronautics Advanced Manufacturing Center (CFAA), Biskay Technology Park, Bilbao, 48170, Biscay, SpainDepartment of Mechanical Engineering, Faculty of Engineering of Bilbao, Basque Country University (UPV/EHU), Alameda de Urquijo, Bilbao, 48013, Biscay, Spain; Aeronautics Advanced Manufacturing Center (CFAA), Biskay Technology Park, Bilbao, 48170, Biscay, SpainAeronautics Advanced Manufacturing Center (CFAA), Biskay Technology Park, Bilbao, 48170, Biscay, SpainDepartment of Mechanical Engineering, Faculty of Engineering of Bilbao, Basque Country University (UPV/EHU), Alameda de Urquijo, Bilbao, 48013, Biscay, Spain; Aeronautics Advanced Manufacturing Center (CFAA), Biskay Technology Park, Bilbao, 48170, Biscay, SpainCenter for Innovation in Modelling and Optimization of Systems - CIMOS, Center for Innovation in Sustainable Manufacturing - CIMS, Department of Mechanical and Industrial Engineering, Federal University of São João del-Rei (UFSJ), Frei Orlando Square, São João del-Rei, 36307-352, MG, BrazilDepartment of Mechanical Engineering, Faculty of Engineering of Bilbao, Basque Country University (UPV/EHU), Alameda de Urquijo, Bilbao, 48013, Biscay, Spain; Aeronautics Advanced Manufacturing Center (CFAA), Biskay Technology Park, Bilbao, 48170, Biscay, SpainAero-engine components are subjected to extreme service conditions, requiring high-quality holes, extended tool life, and sustainable operations during machining. This study investigates the helical milling of Inconel 718 using a hybrid cryogenic and minimal quantity lubrication (MQL) lubri-cooling strategy. The performance of this method is compared to conventional flood coolant and MQL strategies in terms of tool life, cutting forces, hole quality, and wear mechanisms. The cryogenic/MQL lubri-cooling approach achieved the longest tool life, followed by flood coolant and MQL, producing 20% more holes than in the coolant case and 71.43% more holes than in the MQL case. Roughness results obtained in the last hole machined under the cryo-MQL environment outperformed those of the last hole machined under the coolant and MQL environments by 12.76% and 16%, respectively. However, the cryogenic/MQL strategy exhibited the highest cutting forces, possibly due to material embrittlement caused by the low-temperature environment. The MQL strategy resulted in the shortest tool life, attributed to severe chip adhesion caused by the low lubrication flow rate. Adhesion was identified as the primary wear mechanism, with additional evidence of abrasion, and built-up edges. Nonparametric Friedman rank-sum and Wilcoxon tests revealed statistically significant differences among all lubri-cooling conditions for the first seven holes. The cryogenic/MQL strategy demonstrated the lowest wear, followed by flood coolant and MQL.http://www.sciencedirect.com/science/article/pii/S2590123025008539Helical millingInconel 718Cryogenic coolingMinimum quantity lubricationHybrid lubri-cooling |
| spellingShingle | Robson Bruno Dutra Pereira Gaizka Gómez-Escudero Amaia Calleja-Ochoa Octavio Pereira Haizea González-Barrio Lincoln Cardoso Brandão Luis Norberto López de Lacalle Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718 Results in Engineering Helical milling Inconel 718 Cryogenic cooling Minimum quantity lubrication Hybrid lubri-cooling |
| title | Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718 |
| title_full | Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718 |
| title_fullStr | Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718 |
| title_full_unstemmed | Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718 |
| title_short | Hybrid cryogenic/MQL helical milling for hole-making of Inconel 718 |
| title_sort | hybrid cryogenic mql helical milling for hole making of inconel 718 |
| topic | Helical milling Inconel 718 Cryogenic cooling Minimum quantity lubrication Hybrid lubri-cooling |
| url | http://www.sciencedirect.com/science/article/pii/S2590123025008539 |
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