Size effect and micro endmilling performance while sustainable machining on Inconel 718

Abstract

ABSTRACT Micro endmilling is emerged as a potential micromachining technique in many industries like biomedical, aerospace, optics, electronics and marine, etc. due to the huge demand for micro components with precision. However, relatively higher tool wear and poor surface characteristics are limiting its applicability in many areas. Therefore, the need has been raised to improve the machining characteristics of micro endmilling sustainably. The size effect and micro endmilling performance such as wear behavior, cutting force, and microhardness under dry and sunflower oil based MQL environments while machining on Inconel 718 was studied in this work. Results showed that the sunflower oil based MQL environments have the potential to reduce the size effect region and tool wear significantly. Workpiece adhesion and abrasion on the cutting edge were identified as the main underlying wear mechanism for both conditions. The edge radius, tool flank wear, and cutting forces were found to be reduced by 25%, 30%, and 36% respectively with the application of MQL compared to dry conditions. In addition, an increase of 7% in microhardness with relatively smooth surfaces as well as reduced micro cracks, prows, and voids on the machined surfaces were observed with the application of MQL.