Optimization of cutting parameters using response surface methodology (RSM) in milling Inconel 718 superalloy using Borax-added nanofluid in (MQL) system

Abstract

Purpose The need for materials with superior mechanical and physical properties has recently increased. Inconel 718, one of these superalloys, is frequently used in the aviation and space industry. However, during Inconel 718 superalloy machining, cutting tools and cutting fluid were excessively consumed. This study aims to investigate using an innovative and environmentally friendly cutting fluid in milling the Inconel 718 superalloy. Design/methodology/approach In this study, a Borax- (BX-)added cutting nanofluid was prepared and used for the first time as a coolant in the minimum quantity lubrication (MQL) system of Inconel 718’s face milling process. Response surface methodology (RSM) was used to determine the effect of the BX element on cutting performance. Face milling operations were carried out by adding BX elements at 1.5% and 3% at two different rates. Findings As the BX additive ratio in the cutting fluid used in the MQL system increased, the cutting force values decreased. The lowest cutting force value was measured in the tests with cutting fluid containing 1.5% BX. In addition, a smoother surface was obtained by adding 1.5% BX to the cutting fluid. Furthermore, cutting tool life increased by 20% compared to 0% by 3% BX nanofluid concentration. Originality/value The study is innovative regarding the material processed, the cutting fluid used and the method used for the aerospace industry. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0191/