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<p>Conventional drilling of difficult-to-machine alloys often results in poor surface integrity and excessive tool wear. Furthermore, with stringent environmental policies promoting eco-friendly practices and a growing emphasis on sustainable manufacturing, there is an increasing need for cleaner and more efficient machining techniques. To address these challenges, the present study investigated the effects of ultrasonic-assisted drilling (UAD) using bio-inspired textured drills in combination with minimum quantity lubrication (MQL) on the surface integrity of Nimonic 80&#xa0;A. The present study examined tool wear, surface characteristics, microhardness, residual stresses, microstructural behaviour, and life cycle assessment (LCA). Residual stresses were determined using X-ray diffraction (XRD), whereas microstructural evolution was analysed by electron backscatter diffraction (EBSD). The results showed that the synergistic application of ultrasonic vibration, a bio-inspired textured tool, and green cutting fluid (Mahua oil) under MQL conditions significantly improved surface integrity. In comparison with the conventional drilling strategy, the surface roughness (Ra) decreased by 29.79, 40.88, and 63.32% for the CDT + MQL, UADT, and UADT + MQL processes, respectively. Notably, the UADT + MQL process generated higher compressive residual stresses than other drilling techniques, while inducing minimal microstructural alterations. Also, this method demonstrated improved tool life compared to its counterparts. A comprehensive sustainability assessment revealed that the combined UADT + MQL approach is more environmentally sustainable than conventional drilling with textured tool. Overall, the findings confirmed that the UADT + MQL scheme is an efficient, sustainable, and high-performance drilling technique for superalloy materials.</p> Graphic Abstract <p></p>

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Sustainable Ultrasonic-Assisted Drilling of Nimonic 80A Using Bio-inspired Textured Tools: Surface Integrity Assessment

  • 期刊论文

  • 发表日期：

    2026年6月1日

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  • Vinod Singh Rajput,
  • Aswani Kumar Singh,
  • Varun Sharma

摘要

Conventional drilling of difficult-to-machine alloys often results in poor surface integrity and excessive tool wear. Furthermore, with stringent environmental policies promoting eco-friendly practices and a growing emphasis on sustainable manufacturing, there is an increasing need for cleaner and more efficient machining techniques. To address these challenges, the present study investigated the effects of ultrasonic-assisted drilling (UAD) using bio-inspired textured drills in combination with minimum quantity lubrication (MQL) on the surface integrity of Nimonic 80 A. The present study examined tool wear, surface characteristics, microhardness, residual stresses, microstructural behaviour, and life cycle assessment (LCA). Residual stresses were determined using X-ray diffraction (XRD), whereas microstructural evolution was analysed by electron backscatter diffraction (EBSD). The results showed that the synergistic application of ultrasonic vibration, a bio-inspired textured tool, and green cutting fluid (Mahua oil) under MQL conditions significantly improved surface integrity. In comparison with the conventional drilling strategy, the surface roughness (Ra) decreased by 29.79, 40.88, and 63.32% for the CDT + MQL, UADT, and UADT + MQL processes, respectively. Notably, the UADT + MQL process generated higher compressive residual stresses than other drilling techniques, while inducing minimal microstructural alterations. Also, this method demonstrated improved tool life compared to its counterparts. A comprehensive sustainability assessment revealed that the combined UADT + MQL approach is more environmentally sustainable than conventional drilling with textured tool. Overall, the findings confirmed that the UADT + MQL scheme is an efficient, sustainable, and high-performance drilling technique for superalloy materials.

Graphic Abstract