Investigation of surface modification and tool wear on milling Nimonic 80A under hybrid lubrication

Friction at cutting interfaces deteriorates the nascent surfaces and influences the wear of tool (tool life) that causes the cost of manufacturing. Hybrid cooling/lubrication has been used to machine Nimonic 80A which is challenging to machine conventionally due to its poor heat diffusivity and superior chemical attraction. The focus was on the surface modification (roughness, topography, residual stress, microhardness) and wear phenomenon of the tools under the hybrid cryogenic minimum quantity lubrication (CMQL) approach. Compressive residual stress, increased microhardness (4–9%), and less tool wear (22–71%) were few benefits of CMQL compared to the traditional approach. Concurrent action of chilling and lubrication enabled lower temperatures, higher compressive residual stress, microhardness, and surface quality. Abrasion and adhesion were dominant wear modes.