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    Thermo-physical, tribological and machining characteristics of Hastelloy C276 under sustainable cooling/lubrication conditions
    (Elsevier Sci Ltd, 2022) Ross, Nimel Sworna; Srinivasan, N.; Amutha, P.; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi
    Chemical reactivity and poor heat conductivity make nickel (Ni) and its alloys difficult to process. The aerospace industry's expectations for high-quality surfaces are one of the biggest hurdles in machining nickel components. Recent studies have found some flaws in mist lubrication techniques when utilised under high-speed cutting circumstances, thus nanoparticles with higher thermal conductivity than the base fluid is now being used in minimum quantity lubrication (MQL) systems. Nanocarbon dots (CDs) blended with bio lubricant is an effective coolant to enhance the heat transfer capability by decreasing friction. The inclusion of the right nanoparticle ratio to the base liquid is one of the most important challenges that arise when machining. This research focuses on a deeper exploration of Hastelloy C276's tribological behaviour and machinability under various cutting approaches (Dry, MQL Cryo CO2 and N-MQL). Milling trials were carried out with various speed-feed pairings and cutting conditions. Outcomes show that 0.8 wt% CDs with soybean oil reduces the surface roughness by 56-69 %, 15-24 %, and 15-26 % over dry, MQl and cryo CO2 environments. According to elemental study of cutting inserts, adhesion is the primary wear mechanism in all cutting mediums. Finally, the chillness produced by cryo CO2 has a positive effect compared to the N-MQL strategy by producing fine grains.
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    Tribology-driven strategies for tool wear reduction and surface integrity enhancement in cryogenic CO2-cooled milling of laser metal deposited Ti64 alloy
    (Elsevier Sci Ltd, 2024) Ross, Nimel Sworna; Mashinini, Peter Madindwa; Ananth, M. Belsam Jeba; Srinivasan, N.; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi
    Additive manufacturing (AM) is chosen for its ability to streamline production processes and design freedom. This reduces material waste, enables rapid prototyping, and facilitates intricate geometries, ultimately offering cost-effective and customizable solutions for manufacturing complex components in diverse industries. Overlapping melting trajectories result in a low-quality surface (Ra=similar to 13.34 mu m) in the laser metal deposition (LMD) of the Ti64 alloy. Therefore, post-processing is often essential for AMed parts for engineering applications. Milling trials were conducted on AMed specimens under four environmental conditions: dry, flood, minimum quantity lubrication (MQL), and cryogenic medium. The machinability was evaluated in terms of the cutting temperature, machined surface roughness, tool wear, chip morphology, and microhardness. The flank wear under cryogenic CO2 condition is 52.78-54.29 % lower than dry condition, 33.86-36.24 % lower than flood cutting, and 23.64-26.86 % lower than MQL. The outcomes show that cryogenic cooling augments the tool life and the surface integrity of milling LMD parts. Moreover, the hardness under cryogenic CO2 was higher, indicating dimensional stability and maintenance of shape integrity under applied loads.