Rough turning Inconel 750 with supercritical CO2-based minimum quantity lubrication |
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| Affiliation: | 1. Fusion Coolant Systems, Detroit, MI 48238-4243, USA;2. Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125, USA;3. King Technical Services, Ann Arbor, MI 48104-4906, USA;1. Centre for Additive Manufacturing, School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University, PO Box 2476, Melbourne, Victoria 3001, Australia;2. Faculty of Engineering and Industrial Sciences, Swinburne University of Technology, Hawthorn, Victoria 3122, Australia;3. Queensland Centre for Advanced Materials Processing and Manufacturing (AMPAM), School of Mining and Mechanical Engineering, the University of Queensland, St Lucia, Brisbane, Queensland 4072, Australia;4. Defence Materials Technology Centre, Hawthorn, Victoria 3122, Australia;1. Faculty of Mechanical Engineering, University of Ljubljana, Askerceva 6, SI-1000 Ljubljana, Slovenia;2. Institute for Sustainable Manufacturing (ISM), University of Kentucky, Lexington, Kentucky 40506-0108, USA;3. University of Lyon, ENISE, LTDS, CNRS UMR5513, 42023 Saint-Etienne, France;4. Faculty of Electrical Engineering, University of Ljubljana, Trzaska 25, SI-1000 Ljubljana, Slovenia;1. Arts et Metiers, LaBoMaP, UBFC, 71250 Cluny, France;2. Univ Lyon, ENISE LTDS, CNRS UMR5513, 58 Rue Jean Parot, 42023 Saint-Etienne cedex 2, France;1. Department of Mechanical Engineering, University of The Basque Country (UPV/EHU), C/ Alameda de Urquijo s/n, Bilbao, E-48013, Spain;2. Fundació Privada Centre CIM, C/ Llorens i Artigas 12, Barcelona, 08028, Spain;3. Tecnalia, Parque Tecnológico de San Sebastián Mikeletegi Pasealekua 7, San Sebastián, E-20009, Spain;4. Department of Mechanical Engineering, Universitat Politècnica de Catalunya (UPC), Avda. Diagonal 647, Barcelona, 08028, Spain;1. Department of Mechanical Engineering, University of The Basque Country (UPV/EHU), C/ Alameda de Urquijo s/n, Bilbao, E-48013, Spain;2. Department of Mechanical, Computer and Aerospace Engineering, University of Leon (uLe), Campus de Vegazana s/n, León, E-24071, Spain |
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| Abstract: | This paper describes preliminary results of replacing water-based (aqueous) flood coolant with supercritical CO2-based minimum quantity lubrication (scCO2 MQL) in an external turning operation on an Inconel 750 combustor housing. Two series of tests were performed: the first series to compare tool wear performance observed with aqueous flood coolant and scCO2 MQL under identical machining conditions, and the second series to investigate tool wear performance with scCO2 MQL at higher metal removal rates (MRR) than the MRR used in production practice with aqueous flood coolant. All tests were performed using roughing cuts on unaged Inconel with coated carbide tooling, and vegetable oil lubricant. As a key enabler, special flank jet tool holders were used to eliminate chip blockage of the lubricant stream.In the first series of tests, tool wear was observed to be consistently lower with scCO2 MQL than with the aqueous flood coolant. In the second series of tests, two process conditions were demonstrated for which MRR increased by 25% and 40%, respectively, with scCO2 MQL compared to aqueous flood coolant at equivalent tool life. Notch wear, the limiting factor for tool life under baseline conditions, was reduced for scCO2 MQL, but crater wear and chip hammering were more pronounced. Overall the results indicate that scCO2 MQL can provide increased tool life or material removal rate compared to aqueous flood coolants when machining Inconel 750 and similar nickel alloys by improving lubricity and changing the dominant wear mechanism from rapid notch wear to gradual crater wear and chip hammering. These tests, which involved extended cuts of over 10 min under production conditions, represent an important extension of MQL machining to a hard metal alloy that cannot be machined by conventional MQL methods. |
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| Keywords: | Tool life Minimum quantity lubrication Supercritical carbon dioxide Inconel |
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