Tool Wear Behavior in μ-Turning of Nimonic 90 Under Vegetable Oil-Based Cutting Fluid

Abstract

Abstract The characteristics such as high hardness and shear modulus, low thermal conductivity, strain hardening of Nickel-based superalloys lead to high machining forces and temperature, poor surface quality and integrity, rapid tool wear, etc. The present article investigates the tool wear mechanism of the tungsten carbide (WC) tool in μ-turning of Nimonic 90 under dry, wet, and vegetable oil-based cutting fluid (VCF). Canola oil is used as vegetable oil. Three different combinations of cutting speed, feed rate, and depth of cut are considered for analysis. The tool wear is characterized using optical and scanning electron microscopy. Machining with VCF shows an approximate reduction of flank wear width in the range of 12–52% compared to dry and wet conditions. The main wear mechanisms observed on the tool flank and rake face are abrasion, built-up edge adhesion, and edge chipping. The VCF considerably reduces the adhesion and abrasion and, hence, increases tool life. The chips produced in dry conditions are found fractured and uneven, whereas, it had an uneven lamella structure in wet conditions. The VCF found reducing the plastic deformation in each cutting condition, as a result, producing fine lamella structured chips.