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    Impact of hybrid cooling approach on milling and surface morphological characteristics of Nimonic 80A alloy
    (Elsevier Sci Ltd, 2022) Ross, Nimel Sworna; Gopinath, C.; Nagarajan, Srinivasan; Gupta, Munish Kumar; Shanmugam, Ragavanantham; Kumar, M. Saravana; Boy, Mehmet
    Poor surface traits, short insert life, high manufacturing costs, and low productivity are associated with the machining of nickel alloys. Cutting fluids have well-known positive and negative effects on machinability performance. As a result, the machining industry has developed green cutting environments such as vegetable oil assisted minimum quantity lubrication (MQL) and cryogenic cooling. Despite the fact that MQL and cryogenic approaches can replace mineral oil-based flooding, their lack of lubrication and cooling properties at high speeds have prompted a search for a new hybrid approach (CO2 + MQL) that provides adequate cooling/lubrication (C/L). Moreover, as of now, no information concerning the effects of hybrid cooling on milling of Nimonic-80A is existing. To test the viability, the machining of Nimonic-80A under hybrid C/L was compared to other cutting environments (MQL and cryogenic). As crucial machinability factors, temperature, power consumption, surface and subsurface characteristics were thoroughly examined. Hybrid condition curtailed the burr formation, which paves the way for a reduction in specific cutting energy (SCE). The experimental results indicate that the hybrid condition considerably decreases the temperature and SCE by 34-53% and 17-19% in comparison with the MQL condition. Peak widening and intensity reduction were seen in the XRD examination, but no phase transition was found. Smaller grain size shows the superiority of hybrid environment.
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    A new approach of measurement and analysis of PVD - TiAlN coated carbide tools in machining of Monel 400 alloy under hybrid cooling conditions
    (Elsevier Sci Ltd, 2023) Ross, Nimel Sworna; Gopinath, C.; Sivaraman, V.; Ananth, M. Belsam Jeba; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Jamil, Muhammad
    This research work focuses on the efficacy of minimum quantity lubrication (MQL) and cryogenic carbon dioxide (CO2) cooling in high-speed machining of nickel-based alloy. CO2 and MQL supplied in the rake face were compared to CO2 and MQL in turning of Monel 400. Tool wear, temperature, surface roughness, and micro -structural assessments were done to compute the cooling influence of distinct approaches. Energy dispersive spectrometry (EDS) mapping is employed to investigate the abrasion and adhesion mechanisms. The wear levels were reduced under the use of the hybrid approach; the decrease in flank wear value relative to the hybrid condition is 78%, 36%, and 27%, and in terms of crater wear, the reduction was 78%, 54%, and 48% over dry, MQL, and cryo CO2 conditions, respectively. Findings have portrayed that the lessening of temperature at the cutting area with the hybrid condition reduces the roughness by 58%, 44%, and 20% over dry, MQL, and cryo CO2 cutting strategies, respectively. Moreover, verdicts of the investigation confirm smaller grain size and high hardness under cryo cooling condition.