Dimensional and Surface Quality Evaluation of Inconel 718 Alloy After Grinding with Environmentally Friendly Cooling-Lubrication Technique and Graphene Enriched Cutting Fluid
Abstract
1. Introduction
2. Materials and Methods
2.1. Material Characterization
2.2. Grinding Parameters
Cooling-Lubrication Condition (CLC)
- Flood: semi-synthetic emulsifiable oil, Vasco 7000 from Blaser Swisslube (Blaser Swisslube, Hasle-Rüegsau, Switzerland), diluted in water in a proportion of 1:9, which was monitored with the aid of a refractometer (N1, ATAGO). The coolant was delivered with a pressure near to the atmospheric one and with a flow rate of 522 L/h (522,000 mL/h).
- MQL WG: WG stands for without multilayer graphene platelets, i.e., only oil. In this condition the oil (Vasco 7000) was delivered without water and solid particles. The flow rate and compressed-air pressure for the MQL technique were 240 mL/h and 0.5 MPa, respectively, for all the tests using the MQL technique;
- MQL MG 0.05%: this condition refers to Vasco 7000 oil with multilayer graphene (MG) platelets added as 0.05% by weight, applied via the MQL technique;
- MQL MG 0.10%: this refers to Vasco 7000 oil with multilayer graphene platelets added as 0.10% by weight, also applied via the MQL technique.
2.3. Dimensional Measurements
- (1)
- Fixation of workpiece in the precision vise;
- (2)
- Preparation of the workpiece surface by grinding with the same cutting parameters detailed in Table 4, with the exception of radial depth of cut, which was equal to 10 µm, i.e., soft grinding conditions;
- (3)
- The set (vise + workpiece), gauge blocks, and the analog outside micrometer were kept on a granite table in a temperature-controlled room for 12 h to ensure the measurement temperature of 20 °C;
- (4)
- A gauge block was used to avoid errors due to the vise geometry;
- (5)
- Measurements were performed following all the statistical recommendations;
- (6)
- The set was put in the same room as the grinder machine for 12 h before the grinding trial to achieve thermal balance;
- (7)
- The grinding operation was performed;
- (8)
- The set was cleaned;
- (9)
- Step 3 was repeated to ensure the proper measurement temperature of 20 °C;
- (10)
- Measurements of the height of workpieces included ten measurements for each workpiece;
- (11)
- Repetition of tests for the different cutting parameters and colling-lubrication conditions and replica.
- Definition of the measurand or output variable;
- Identification of input variables that may affect the measurement of the output variable;
- Mathematical model of the measurand as a function of all input variables;
- Calculation of the standard uncertainty associated with each input variable (u);
- Calculation of the combined standard uncertainty regarding the output variable (uc);
- Calculation of effective degrees of freedom;
- Assessment of the expanded uncertainty regarding roughness (U);
- Mathematical expression of the measurement result.
2.4. Surface Roughness and Surface Morphology
2.5. Instant Grinding Power Measurements
2.6. Design of Experiment (DOE) and Statistical Analysis
3. Results and Discussion
3.1. Removed Height and Dimensional Tolerance After Grinding
3.2. Surface Finish and Surface Morphology
3.3. Electric Power
4. Conclusions
- Considering the lowest depth of cut (ae = 20 µm), the dimensional accuracy in terms of International Tolerance (IT) grade was in the range from IT5–IT6 for flood and MQL WG (only oil), and IT6–IT7 for MQL MG 0.05% and MQL MG 0.10%;
- The improved lubricating properties of the MQL MG 0.10% contributed to reduce the friction of material sliding through abrasive grits with no material removal, thereby reducing the removed height in comparison to the other cooling-lubrication conditions;
- Grinding with radial depth of cut (ae) of 40 µm increased the removed material in comparison to the lower ae (20 µm). In terms of the cooling-lubrication conditions tested, the MQL WG resulted in the lowest International Tolerance (IT) grade (IT6–IT7), followed by MQL MG 0.10% (IT7), MQL MG 0.05% (IT7–IT8), and flood (IT8);
- Overall, regardless of the ae, the MQL without graphene (MQL WG) was the condition in which the removed height was closest to the set depth of cut;
- With respect to the multilayer graphene (MG), its presence in the cutting fluid contributed to reducing the removed height due to an enhanced micro-plowing mechanism, thereby indicating an improvement in lubrication capacity related to plastic deformation with no material removal. Additionally, the reduction in the removed height when grinding with MG suggests lower thermal expansion of the workpiece during grinding, which may be associated with better temperature control;
- The addition of multilayer graphene (MG) significantly reduced Ra roughness, and the condition MQL MG 0.05% outperformed others when grinding with the severest cutting condition (ae = 40 µm);
- Evidence of intense plastic deformation occurred when grinding with MG and ae = 20 µm, indicating that micro-plowing was the predominant mechanism during chip formation. This characteristic was also observed when grinding at the highest depth of cut value combined with the MQL WG condition, possibly associated with insufficient cooling capacity of the MQL technique without MG;
- The electric power increased with the radial depth of cut due to the higher chip thickness, which led to more material being removed from the workpiece, which increases grinding forces and electric power as well. The highest measured values were obtained for the MQL WG condition being 1.24 kW and 1.91 kW for ae equal to 20 µm and 40 µm, respectively. The lowest values for ae = 20 µm were 0.82 kW measured for the MQL 0.10% condition and for ae = 40 µm it was 1.51 kW as a result of the MQL 0.05% condition;
- With respect to the influence of CLC on the electric power, the lower values were obtained for the conditions with MG, evidencing that the presence of MG at the contact zone in fact improved lubrication, even resulting in no material removal (micro-plowing) when grinding with ae = 20 µm, and that a reduction in friction force strongly reduces the total grinding force, and therefore reduces the grinding power;
- The use of the MQL technique with graphene enriched cutting fluids can improve Inconel 718’s grindability in terms of surface finish and electric power, although slightly increasing dimensional deviation in comparison to traditional MQL (only oil). Thus, based on the findings of this work, these cooling-lubrication conditions can replace the flood technique for a more environmentally sustainable grinding process.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Tensile Strength (σt—MPa) | Yield Strength (σy—MPa) | Young’s Modulus (E—GPa) | Hardness (HRC) | Density at Room Temperature (ρ—g/cm3) | Melting Range (°C) | Thermal Conductivity (λ—W/mK) |
---|---|---|---|---|---|---|
1275 | 1034 | 200 | 40 | 8.22 | 1260–1336 | 11.4 |
Element | C | Al | Ti | Cr | Fe | Ni | Nb | Mo |
---|---|---|---|---|---|---|---|---|
Percentage | 0.04 | 0.50 | 0.90 | 19.00 | 18.50 | 50.66 | 5.10 | 5.30 |
Parameter | Cutting Speed (vs) | Workspeed (vw) | Radial Depth of Cut (ae) |
---|---|---|---|
Value | 38 m/s | 10 m/min | 20 µm; 40 µm |
Dynamic Viscosity (m·Pa·s) | Thermal Conductivity (W·m−1K−1) × 10−001 | |||
---|---|---|---|---|
At 25 °C | At 50 °C | At 25 °C | At 50 °C | |
Flood (oil + water) | 1.38 ± 0.01 | 0.86 ± 0.00 | 5.41 ± 0.08 | 5.00 ± 0.22 |
MQL WG | 145.2 ± 0.41 | 44.82 ± 0.03 | 2.65 ± 0.04 | 2.64 ± 0.05 |
MQL MG 0.05% | 157.18 ± 2.05 | 48.53 ± 0.54 | 2.83 ± 0.13 | 2.85 ± 0.21 |
MQL MG 0.10% | 159.42 ± 0.74 | 48.97 ± 0.08 | 2.81 ± 0.31 | 1.65 ± 0.21 |
Quantity | Estimation | P. D | T. A | D. F | C. S | Standard Uncertainty |
---|---|---|---|---|---|---|
t | A | n − 1 | 1 | |||
∆Rm | Rm | R | B | ∞ | 1 | |
ΔCm | 0.0015 mm | t | B | ∞ | 1 |
Test | Cooling-Lubrication Condition (CLC) | Radial Depth of Cut (ae) [µm] |
---|---|---|
1 | Flood | 20 |
2 | 40 | |
3 | MQL WG (only oil) | 20 |
4 | 40 | |
5 | MQL MG 0.05 wt. % | 20 |
6 | 40 | |
7 | MQL MG 0.10 wt. % | 20 |
8 | 40 |
Nominal Dimension (mm) | International Tolerance (IT) Grade | |||||||||
---|---|---|---|---|---|---|---|---|---|---|
IT1 | IT2 | IT3 | IT4 | IT5 | IT6 | IT7 | IT8 | IT9 | ||
Above | Up to (Including) | Tolerance (µm) | ||||||||
6 | 10 | 1.0 | 1.5 | 2.5 | 4.0 | 6.0 | 9.0 | 15.0 | 22.0 | 36.0 |
10 | 18 | 1.2 | 2.0 | 3.0 | 5.0 | 8.0 | 11.0 | 18.0 | 27.0 | 43.0 |
18 | 30 | 1.5 | 2.5 | 4.0 | 6.0 | 9.0 | 13.0 | 21.0 | 33.0 | 52.0 |
30 | 50 | 1.5 | 2.5 | 4.0 | 7.0 | 11.0 | 16.0 | 25.0 | 39.0 | 62.0 |
Flood | MQL WG | MQL MG 0.05% | MQL MG 0.10% | ||
---|---|---|---|---|---|
Removed height (mean value ± expanded uncertainty) [µm] | 10 ± 2 | 11 ± 2 | 7 ± 2 | 5 ± 2 | |
Difference between removed height and set radial depth of cut (20 µm) | Highest deviation [µm] | 12 | 11 | 15 | 17 |
Lowest deviation [µm] | 8 | 7 | 11 | 13 | |
International tolerance grade for nominal dimension up to 30 mm | IT5–IT6 | IT5–IT6 | IT6–IT7 | IT6–IT7 |
Flood | MQL WG | MQL MG 0.05% | MQL MG 0.10% | ||
---|---|---|---|---|---|
Removed height (mean value ± expanded uncertainty) [µm] | 17 ± 3 | 27 ± 1 | 9± 2 | 23 ± 2 | |
Difference between removed height and set radial depth of cut (40 µm) | Highest deviation [µm] | 26 | 14 | 29 | 15 |
Lowest deviation [µm] | 20 | 12 | 33 | 19 | |
International tolerance grade for nominal dimension up to 30 mm | IT8 | IT6–IT7 | IT7–IT8 | IT7 |
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de Oliveira, D.; de Paiva, R.L.; Pereira, M.F.; Arencibia, R.V.; Gelamo, R.V.; da Silva, R.B. Dimensional and Surface Quality Evaluation of Inconel 718 Alloy After Grinding with Environmentally Friendly Cooling-Lubrication Technique and Graphene Enriched Cutting Fluid. Appl. Mech. 2025, 6, 50. https://doi.org/10.3390/applmech6030050
de Oliveira D, de Paiva RL, Pereira MF, Arencibia RV, Gelamo RV, da Silva RB. Dimensional and Surface Quality Evaluation of Inconel 718 Alloy After Grinding with Environmentally Friendly Cooling-Lubrication Technique and Graphene Enriched Cutting Fluid. Applied Mechanics. 2025; 6(3):50. https://doi.org/10.3390/applmech6030050
Chicago/Turabian Stylede Oliveira, Déborah, Raphael Lima de Paiva, Mayara Fernanda Pereira, Rosenda Valdés Arencibia, Rogerio Valentim Gelamo, and Rosemar Batista da Silva. 2025. "Dimensional and Surface Quality Evaluation of Inconel 718 Alloy After Grinding with Environmentally Friendly Cooling-Lubrication Technique and Graphene Enriched Cutting Fluid" Applied Mechanics 6, no. 3: 50. https://doi.org/10.3390/applmech6030050
APA Stylede Oliveira, D., de Paiva, R. L., Pereira, M. F., Arencibia, R. V., Gelamo, R. V., & da Silva, R. B. (2025). Dimensional and Surface Quality Evaluation of Inconel 718 Alloy After Grinding with Environmentally Friendly Cooling-Lubrication Technique and Graphene Enriched Cutting Fluid. Applied Mechanics, 6(3), 50. https://doi.org/10.3390/applmech6030050