On the tribological and thermal aspects of cryogenic machining of Inconel 718 and their effects on surface integrity
(2025) In Wear 571.- Abstract
Current trends aim at improving the surface integrity of aerospace Ni-based superalloys by reducing the temperature rise in the cutting zone in order to minimize tool wear, as well as reducing the thermally induced tensile residual stresses on the machined surface. The manufacturing industry is also driven by developing high performance sustainable machining processes. Cryogenic machining (CM) using Liquid Nitrogen (LN2) has recently gained interest and momentum as a clean and economical cooling technique, especially for applications involving aggressive metal removal of hard-to-cut materials. This research aims at understanding the physical, thermal and tribological aspects of LN2 cryogenic machining and optimizing the machining... (More)
Current trends aim at improving the surface integrity of aerospace Ni-based superalloys by reducing the temperature rise in the cutting zone in order to minimize tool wear, as well as reducing the thermally induced tensile residual stresses on the machined surface. The manufacturing industry is also driven by developing high performance sustainable machining processes. Cryogenic machining (CM) using Liquid Nitrogen (LN2) has recently gained interest and momentum as a clean and economical cooling technique, especially for applications involving aggressive metal removal of hard-to-cut materials. This research aims at understanding the physical, thermal and tribological aspects of LN2 cryogenic machining and optimizing the machining process based on computational fluid dynamics CFD analysis results. Experimental investigation of the turning operation of Inconel 718 (IN718) were carried out at different LN2 delivery configurations and compared to high pressure coolant (HPC) and flood cooling. The effect of the cooling strategy on the machining performance was evaluated in terms of tool wear, friction at the tool-chip interface and surface integrity of machined parts. Progressive tool wear tests showed a 20 % reduction in tool wear compared to high pressure cooling. This can be attributed to the effective penetration of LN2 to the cutting area (tool-chip contact interface, and the cutting edge), which leads to improve the cooling and lubrication capacity of the LN2 jet. Residual stresses measurement in the subsurface layer of machined parts showed that a tensile residual stress of 50 MPa at the surface was obtained for flood cooling, due to the high cutting temperature. On the other hand, cryogenic cooling produced compressive residual stresses of up to 600 MPa at the surface, which are very beneficial for the part quality and fatigue life.
(Less)
- author
- Damir, Ahmed ; Shi, Bin ; Elsayed, Ahmed ; Thelin, Jimmy ; M'Saoubi, Rachid LU and Attia, Helmi
- organization
- publishing date
- 2025-06
- type
- Contribution to journal
- publication status
- published
- subject
- keywords
- Cryo-tribology, Cutting, Modelling, Tool wear
- in
- Wear
- volume
- 571
- article number
- 205855
- publisher
- Elsevier
- external identifiers
-
- scopus:85217889326
- ISSN
- 0043-1648
- DOI
- 10.1016/j.wear.2025.205855
- language
- English
- LU publication?
- yes
- id
- 059a6eab-c5a4-4b1e-8d66-d2a09331f90d
- date added to LUP
- 2025-07-04 09:05:12
- date last changed
- 2025-07-04 09:06:29
@article{059a6eab-c5a4-4b1e-8d66-d2a09331f90d,
abstract = {{<p>Current trends aim at improving the surface integrity of aerospace Ni-based superalloys by reducing the temperature rise in the cutting zone in order to minimize tool wear, as well as reducing the thermally induced tensile residual stresses on the machined surface. The manufacturing industry is also driven by developing high performance sustainable machining processes. Cryogenic machining (CM) using Liquid Nitrogen (LN2) has recently gained interest and momentum as a clean and economical cooling technique, especially for applications involving aggressive metal removal of hard-to-cut materials. This research aims at understanding the physical, thermal and tribological aspects of LN2 cryogenic machining and optimizing the machining process based on computational fluid dynamics CFD analysis results. Experimental investigation of the turning operation of Inconel 718 (IN718) were carried out at different LN2 delivery configurations and compared to high pressure coolant (HPC) and flood cooling. The effect of the cooling strategy on the machining performance was evaluated in terms of tool wear, friction at the tool-chip interface and surface integrity of machined parts. Progressive tool wear tests showed a 20 % reduction in tool wear compared to high pressure cooling. This can be attributed to the effective penetration of LN2 to the cutting area (tool-chip contact interface, and the cutting edge), which leads to improve the cooling and lubrication capacity of the LN2 jet. Residual stresses measurement in the subsurface layer of machined parts showed that a tensile residual stress of 50 MPa at the surface was obtained for flood cooling, due to the high cutting temperature. On the other hand, cryogenic cooling produced compressive residual stresses of up to 600 MPa at the surface, which are very beneficial for the part quality and fatigue life.</p>}},
author = {{Damir, Ahmed and Shi, Bin and Elsayed, Ahmed and Thelin, Jimmy and M'Saoubi, Rachid and Attia, Helmi}},
issn = {{0043-1648}},
keywords = {{Cryo-tribology; Cutting; Modelling; Tool wear}},
language = {{eng}},
publisher = {{Elsevier}},
series = {{Wear}},
title = {{On the tribological and thermal aspects of cryogenic machining of Inconel 718 and their effects on surface integrity}},
url = {{http://dx.doi.org/10.1016/j.wear.2025.205855}},
doi = {{10.1016/j.wear.2025.205855}},
volume = {{571}},
year = {{2025}},
}