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<p>This study investigates the combined influence of advanced lubrication and cooling techniques on enhancing the machinability of Monel 400, a nickel-based superalloy widely employed in marine, chemical, and aerospace applications due to its exceptional corrosion resistance and mechanical strength. Four machining conditions—dry cutting, Minimum Quantity Lubrication (MQL), nano-enhanced MQL (NMQL), and a hybrid approach integrating cryogenic liquid nitrogen with NMQL (Cryo + NMQL)—were systematically compared. The experiments were performed using fixed machining parameters: a cutting speed of 80&#xa0;m/min, feed rate of 0.15&#xa0;mm/tooth, radial depth of cut of 6&#xa0;mm, and axial depth of cut of 0.8&#xa0;mm. Among these, Cryo + NMQL, featuring carbon nanotube (CNT)-enriched sunflower oil nanofluid combined with liquid nitrogen (LN₂) as the cryogenic medium, achieved superior outcomes, reducing cutting force, cutting temperature, surface roughness, and tool wear by 23.99%, 24.66%, 44.58%, and 54.85%, respectively, compared to dry cutting. SEM analysis confirmed adhesion and abrasion as dominant wear mechanisms, which were significantly mitigated under Cryo + NMQL. Multi-Objective Response Surface Methodology (MORSM) optimized the machining parameters to achieve an ideal balance of performance metrics, with a composite desirability index of 0.956. This study shows that combining LN₂ cryogenic cooling with CNT-based NMQL provides superior machinability of Monel 400—offering lower forces, temperatures, surface roughness, and tool wear—while contributing new insights for an alloy rarely examined under hybrid cooling environments. The findings validate Cryo + NMQL as an eco-benign, high-performance machining strategy, offering enhanced tool life, improved surface finish, and sustainable outcomes.</p>

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Hybrid cryo-nano MQL strategy for sustainable and high-performance machining of Monel 400

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年12月28日

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  • G. Narsinga Rao,
  • S. Sivalingam,
  • Dipak Patel,
  • D. T. Arunkumar,
  • S. Lakshmi Sankar,
  • Binayak Pattanayak,
  • Shahbaz Juneja,
  • Saurabh Aggarwal,
  • Abhijit Bhowmik,
  • Lema Abate

摘要

This study investigates the combined influence of advanced lubrication and cooling techniques on enhancing the machinability of Monel 400, a nickel-based superalloy widely employed in marine, chemical, and aerospace applications due to its exceptional corrosion resistance and mechanical strength. Four machining conditions—dry cutting, Minimum Quantity Lubrication (MQL), nano-enhanced MQL (NMQL), and a hybrid approach integrating cryogenic liquid nitrogen with NMQL (Cryo + NMQL)—were systematically compared. The experiments were performed using fixed machining parameters: a cutting speed of 80 m/min, feed rate of 0.15 mm/tooth, radial depth of cut of 6 mm, and axial depth of cut of 0.8 mm. Among these, Cryo + NMQL, featuring carbon nanotube (CNT)-enriched sunflower oil nanofluid combined with liquid nitrogen (LN₂) as the cryogenic medium, achieved superior outcomes, reducing cutting force, cutting temperature, surface roughness, and tool wear by 23.99%, 24.66%, 44.58%, and 54.85%, respectively, compared to dry cutting. SEM analysis confirmed adhesion and abrasion as dominant wear mechanisms, which were significantly mitigated under Cryo + NMQL. Multi-Objective Response Surface Methodology (MORSM) optimized the machining parameters to achieve an ideal balance of performance metrics, with a composite desirability index of 0.956. This study shows that combining LN₂ cryogenic cooling with CNT-based NMQL provides superior machinability of Monel 400—offering lower forces, temperatures, surface roughness, and tool wear—while contributing new insights for an alloy rarely examined under hybrid cooling environments. The findings validate Cryo + NMQL as an eco-benign, high-performance machining strategy, offering enhanced tool life, improved surface finish, and sustainable outcomes.