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<p>Surface quality serves as a critical performance indicator in evaluating nickel-based superalloy machining efficiency, particularly in aerospace applications requiring stringent dimensional tolerances and operational reliability. Although near-dry cutting techniques offer environmental benefits, their insufficient thermal regulation and lubrication frequently degrade surface integrity. The combined minimum quantity lubrication (MQL) and vortex tube (VT) cooling system has emerged as an effective solution, providing enhanced heat dissipation and interfacial lubrication with minimal coolant consumption. This hybrid approach improves surface quality through controlled reduction of cutting temperatures and frictional forces. However, systematic analysis of the surface enhancement mechanisms remains challenging. This study experimentally investigates VT-MQL-assisted broaching processes for nickel-based superalloys through cutting force monitoring, thermal characterization, and surface integrity assessment, complemented by finite element simulations. Experimental results indicate that at 0.4 MPa cooling pressure, the VT-MQL system achieves a 40.17% reduction in surface roughness (0.71 µm) while sustaining efficient material removal. The formation of a boundary lubrication film at tool-workpiece interfaces reduces cutting forces by 18.67% (1.47 kN). Finite element analysis demonstrates that temperature–pressure coupling in VT-MQL hybrid systems critically governs cutting performance, with the VT configuration effectively optimizing thermal management and surface quality simultaneously. These findings provide fundamental insights into thermo-mechanical interactions during superalloy machining and establish practical guidelines for cooling strategy optimization.</p>

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Surface quality enhancement by VT-MQL during broaching nickel-based superalloys

  • 期刊论文

  • 发表日期：

    2025年8月5日

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  • Jing Ni,
  • Xinghua Wu,
  • Zhen Meng,
  • Yun Fu,
  • Zefei Zhu,
  • Guozhen Liu,
  • Jinhui Zhou

摘要

Surface quality serves as a critical performance indicator in evaluating nickel-based superalloy machining efficiency, particularly in aerospace applications requiring stringent dimensional tolerances and operational reliability. Although near-dry cutting techniques offer environmental benefits, their insufficient thermal regulation and lubrication frequently degrade surface integrity. The combined minimum quantity lubrication (MQL) and vortex tube (VT) cooling system has emerged as an effective solution, providing enhanced heat dissipation and interfacial lubrication with minimal coolant consumption. This hybrid approach improves surface quality through controlled reduction of cutting temperatures and frictional forces. However, systematic analysis of the surface enhancement mechanisms remains challenging. This study experimentally investigates VT-MQL-assisted broaching processes for nickel-based superalloys through cutting force monitoring, thermal characterization, and surface integrity assessment, complemented by finite element simulations. Experimental results indicate that at 0.4 MPa cooling pressure, the VT-MQL system achieves a 40.17% reduction in surface roughness (0.71 µm) while sustaining efficient material removal. The formation of a boundary lubrication film at tool-workpiece interfaces reduces cutting forces by 18.67% (1.47 kN). Finite element analysis demonstrates that temperature–pressure coupling in VT-MQL hybrid systems critically governs cutting performance, with the VT configuration effectively optimizing thermal management and surface quality simultaneously. These findings provide fundamental insights into thermo-mechanical interactions during superalloy machining and establish practical guidelines for cooling strategy optimization.