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Öğe A state-of-the-art review on tool wear and surface integrity characteristics in machining of superalloys(Elsevier, 2021) Sarikaya, Murat; Gupta, Munish Kumar; Tomaz, Italo; Pimenov, Danil Yu; Kuntoglu, Mustafa; Khanna, Navneet; Yildirim, Cagri VakkasToday, superalloys (also known as hard-to-cut materials) such as nickel, titanium and cobalt based cover a wide range of areas in engineering applications. At the same time, challenging material properties namely high strength and low thermal conductivity cause low quality in terms of cutting tool life and surface integrity of the machined part. It is important to improve the machinability of this type of materials by applying various methods in the perspective of sustainability. Therefore, current study presents surface integrity, tool wear characteristics and initiatives to improve them during the machining of superalloys. In this manner, it is outlined the surface integrity characteristics containing surface defects, surface roughness, microstructure alterations and mechanical properties. Also, tool wear mechanisms for example abrasive, adhesive, oxidation, diffusion and plastic deformation are investigated in the light of literature review. Finally, possible improvement options for tool wear and surface integrity depend on machining parameters, tool modifications, cooling methods and trade-off strategies are highlighted. The paper can be a guide for the researchers and manufacturers in the area of sustainable machining of hard-to-cut materials as explaining the latest trends and requirements. (C) 2021 CIRP.Öğe A study on the influence of thermally assisted novel hybrid methods on the drilling behavior of Ti6Al4V alloy(Elsevier Sci Ltd, 2022) Karabulut, Sener; Bilgin, Musa; Karakoc, Halil; Khanna, Navneet; Sarikaya, MuratThe paper focuses on the drilling behavior of Ti6Al4V alloy under dry, MQL, hot (also expressed as heat-assisted machining), and hybrid (hot+MQL) environments. The surface roughness and morphologies, power consumption, drilling force, microhardness, and microstructural behavior using electron backscatter diffraction (EBSD) analysis were studied. As a result, the lowest roughness value was obtained in the MQL, followed by dry, hot and hybrid drilling environments. Based on SEM investigation on machined surfaces, the defects i.e., smearing, chip debris and side flow were found to be the main causes of poor surface quality, especially under hot and hybrid -assisted drilling environments. According to the Euler color distribution, the hot working affected the machined surface up to the bulk material with a length of 98 mu m. The hot drilling process led to the recrystallization of the grain structure, and the distribution, sizes, and characteristics of the phases were affected by the temperatures. A partially recrystallized grain structure was observed in the IPF maps of the hybrid drilling environment at a distance of 10 mu m from the machined surface. The crystal orientation of machined Ti6Al4V under hybrid-assisted environment was very similar to dry machined crystal orientation indicating stability in the microstructure.Öğe Analysis of machinability and sustainability aspects while machining Hastelloy C4 under sustainable cutting conditions(Elsevier, 2023) Yildirim, cagri Vakkas; Sirin, Senol; Dagli, Salih; Salvi, Harsh; Khanna, NavneetIn recent years, developments in the defense, aerospace, and medical industries have significantly increased the expectations regarding material performances. In particular, the demand for materials that can withstand very high and/or very low temperatures and harsh mechanical/chemical conditions has increased. The superior qualities of superalloys can adequately meet this demand. However, the difficulties encountered in the machining of these alloys cause some burdens both ecologically and economically due to the use of cutting fluid. Therefore, the use of cost-friendly and sustainable cutting fluids in the production industry has a vital role, both in terms of machining performance and the environment. From this perspective, this paper focuses on the effects of various cutting environments, i.e., Dry, MQL, LN2, N-2, CO2, Vortex, LN2 + MQL, N-2 + MQL, CO2 + MQL, and Vortex +MQL on the machining performance of Ni-based C4 alloy. Additionally, it was aimed to reveal the effect of cooling/lubrication methods on sustainability by performing a sustainability analysis. Firstly, surface roughness, power consumption, tool wear and mechanisms, and cutting temperature were considered as performance characteristics. When examined in terms of machinability, Vortex + MQL gave the best result in terms of surface roughness and power consumption, while LN2 gave the best result in terms of cutting temperature. Then, a comprehensive sustainability analysis was carried out. As a result, the CESMO follows the order of Dry > MQL > LN2 > LN(2 +)MQL > CO2 > CO2 + MQL > N-2 > N-2 + MQL > Vortex > Vortex + MQL. While employing Vortex + MQL cutting condition, the CESMO decreased by about 11.37% as compared to Dry cutting condition. While using a combination of different sustainable lubrications or coolants, the overall carbon emissions decreased in the range of about 15-25% approximately as compared to the employment of the individual cutting conditions (i.e., coolant/lubricants).Öğe Application of Environmentally-friendly Cooling/Lubrication Strategies for Turning Magnesium/SiC MMCs(Springer, 2021) Khanna, Navneet; Shah, Prassan; Suri, Narendra Mohan; Agrawal, Chetan; Khatkar, Sandeep K.; Pusavec, Franci; Sarikaya, MuratThe material having high strength to weight ratio is constantly in high demand for automotive industries to increase fuel efficiency. With this view, AZ91/5SiC (an Mg-based Particulate Metal Matrix Composites (PMMCs)) is fabricated using an in-house developed stir casting setup and characterized through Field Emission Scanning Electron Microscopy (FESEM) with Energy-Dispersive X-ray Spectroscopy (EDS) analysis. However, the machinability of PMMCs is found to be lower due to the existence of harder ceramic constituents and appropriate cutting fluid strategies are required to follow to combat this situation. But limited studies are available identifying the impact of recently developed sustainable cooling and lubrication techniques on machining performance when PMMCs is turned. To fill this bridge, customized setups of minimum quantity lubrication (MQL), cryogenic and CryoMQL machining with LN(2)have been developed to provide eco-friendly cutting fluid approaches to turn AZ91/5SiC. The cutting force, energy consumption, surface roughness (R-a) and chip breakability index (C-in) have been analyzed for MQL, cryogenic and CryoMQL techniques with variation in process parameters. By considering the average value of all turning tests, 64.65% and 40.39%; and 11.49% and 7.13% higher value of cutting force and energy consumption is found correspondingly for cryogenic and CryoMQL machining respectively as compared to MQL technique respectively. Overall, 25.59% and 18.35% lower values ofR(a)have been observed for CryoMQL technique as compared with MQL and cryogenic machining respectively. The powder type chips with comparable higher values ofC(in)have been found in all three cooling and lubrication techniques.Öğe Assessing the cooling/lubricating agencies for sustainable alternatives during machining of Nimonic 80: Economic and environmental impacts(Cell Press, 2024) Makhesana, Mayur A.; Vesuwala, Harsh; Patel, Kaushik M.; Vafadar, Ana; Sarikaya, Murat; Khanna, NavneetDeveloping sustainable manufacturing methods that balance environmental and economic aspects is challenging. A comprehensive analysis of the economics of machining and carbon emissions is essential to encourage adopting sustainable practices. This work presents the machinability and comparative sustainability analysis of Nimonic 80 superalloy when it is machined utilizing a novel, environmentally friendly vegetable oil-based hybrid nanofluidminimum quantity lubrication (MQL) and liquid carbon dioxide (LCO2) technique. The main objective is to comprehend the efficacy of the proposed approach on tool life, surface roughness, power consumption, total machining costs, and carbon emissions. Compared to other machining conditions, the use of hybrid nanofluid-MQL under 100 m/min cutting speed prevented rapid flank wear and considerably increased tool life by about 17-59 %. The change in cutting speed from 100 to 150 m/min has resulted in reduced tool life about 13-42 % under the selected environments. In addition, when compared to dry, flood, and MQL machining, the use of hybrid nanofluid-MQL and LCO2 reduced surface roughness by around 16-45 % at 150 m/min. Sustainability analysis revealed that machining at 150 m/min resulted in decreased costs ranging from 6.1 % to 36.4 % for selected cutting environments. Applying hybrid nanofluid-MQL lowered carbon emissions by 16.83 %, whereas LCO2 reduced carbon emissions by 14.6 % at 100 m/min. At 150 m/min, hybrid nanofluid-MQL and LCO2 lowered carbon emission by 22.3 % and 21.5 % at 150 m/min compared to dry machining. Compared to alternative cutting environments, hybrid nanofluid-MQL and LCO2 applications have longer tool lives, lower machining costs, and carbon emissions. As a result, they are economical and environmentally friendly.Öğe Comparative environmental impact assessment of additive-subtractive manufacturing processes for Inconel 625: A life cycle analysis(Elsevier, 2023) Maheshwari, Pratham; Khanna, Navneet; Hegab, Hussien; Singh, Gurminder; Sarikaya, MuratThis paper presents a life cycle assessment (LCA) approach to compare the environmental impacts of additive-subtractive manufacturing processes for Inconel 625. The LCA follows a cradle-to-gate methodology and employs the Eco-chain Mobius Software, in accordance with ISO 14044 standards. The chosen LCA model enables industries to develop sustainable production techniques by evaluating 18 environmental variables' potential effects on human health, ecosystems, and resource availability. The LCA adopts the midpoint(H) approach from ReCiPe 2016 to comprehensively assess the environmental impacts. In the first case study, a plate is created using the Wire Arc Additive Manufacturing (WAAM) method, followed by post-processing through drilling in both wet and dry environments. The dry condition results in a remarkable 24.23% reduction in environmental impact when the LCA is applied to the entire process, making it the most sustainable choice. In the second case study, a hollow cylinder is manufactured using the WAAM technique, and post-processing is conducted using turning processes under cryogenic, dry, and electrostatic minimum quantity lubrication (EMQL) conditions. The dry environment yields a 16.4% lower impact on the environment, establishing it as the most sustainable choice. Overall, the results from both case studies demonstrate that utilizing WAAM technology in a dry environment leads to the most sustainable manufacturing procedure for Inconel 625. This comparative analysis provides valuable insights to support the development of environmentally friendly production techniques in the manufacturing industry.Öğe Comprehensive analysis of tool wear, tool life, surface roughness, costing and carbon emissions in turning Ti-6Al-4V titanium alloy: Cryogenic versus wet machining(Elsevier Sci Ltd, 2021) Agrawal, Chetan; Wadhwa, Jwalant; Pitroda, Anjali; Pruncu, Catalin Iulian; Sarikaya, Murat; Khanna, NavneetCryogenic machining has emerged as a sustainable technique that reflects in terms of reduced environmental effects, superior part quality, and lesser resource consumption. However, further exploration of machinability and sustainability improvements using this technique will help the manufacturing industry to adopt it as an alternative to conventional techniques. In this government-supported work, the machinability of Ti-6Al-4V is assessed at five different cutting speeds (70, 80, 90, 100, and 110 m/min) under wet and cryogenic environments. This article presents a detailed analysis of tool wear (flank and crater wear), power consumption, and surface roughness to seek improvements in machinability of Ti-6Al-4V using cryogenic turning in comparison to wet turning. To investigate the sustainability aspects of cryogenic and wet turning, results are also analyzed in terms of total machining cost and carbon emissions that remain relatively less explored in literature. The results show higher crater wear under a wet environment relative to the cryogenic environment at most of the cutting speeds. However, tool life is improved (by up to 125%) using cryogenic turning in comparison to wet turning exclusively at higher cutting speeds (100 and 110 m/min). Reduced power consumption (by up to 23.4%) and surface roughness (by up to 22.1%) are obtained using cryogenic turning than wet turning at all cutting speeds. It is noted that machining cost is reduced (by up to 27%) using cryogenic turning in comparison to wet turning, especially at higher cutting speeds. Cryogenic turning is proved to be better in terms of environmental aspects as it enables a reduction in overall carbon emissions (by up to 22%) at higher cutting speeds.Öğe Energy consumption and ecological analysis of sustainable and conventional cutting fluid strategies in machining 15-5 PHSS(Elsevier, 2022) Khanna, Navneet; Shah, Prassan; Sarikaya, Murat; Pusavec, FranciRecently, the intense exquisite actions taken by Government authorities generate an immediate requirement to develop more energy-efficient and environment-friendly machining processes. It has been realized to emerge a sustainable alternative to conventional carbon-based coolants in machining processes and select optimum process parameters for reducing the harmful impacts on the environment. However, little literature has been identified which compares the various cutting fluid strategies based on energy consumption and LCA analysis for the combination of the same process parameters and material. Especially, the environmental impacts generated due to nano-cutting fluids are still not explored. Therefore, this study presents the analysis of eight different cutting fluid strategies i.e., Dry, Wet, Minimum Quantity Lubrication (MQL), Electrostatic MQL (EMQL), Hybrid Nanoparticles immersed EMQL (HNPEMQL), Electrostatic Lubrication (EL), LCO2, and LN2 in turning application of 15-5 Precipitated Hardened Stainless Steel (PHSS) at nine different combinations of cutting speeds (vc) and feeds (f). As a result, for the dry and HNPEMQL cutting conditions, the highest and lowest energy consumption have been observed correspondingly. Approximately, 5%, 5%, 8%, 4%, 4%, 5%, and 10% correspondingly higher energy consumption have been identified in EMQL, MQL, EL, Wet, LCO2, LN2, and dry cutting condition in comparison with HNPEMQL. However, HNPEQML was come out as the cutting condition having the highest environmental impact.Öğe Experimental characterisation of the performance of hybrid cryo-lubrication assisted turning of Ti-6Al-4V alloy(Elsevier Sci Ltd, 2021) Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Sarikaya, Murat; Jamil, Muhammad; Mia, Mozammel; Khanna, NavneetIn this work, sustainable hybrid cryogenic MQL cooling/lubrication techniques viz. Banque- Hilsch Vortex tube plus MQL (RHVT + MQL), liquid nitrogen plus minimum quantity lubrication (N2+MQL), and liquid nitrogen (N2) are presented for turning Ti-6Al-4V utilizing CVD coated carbide insert. The tool wear, surface roughness, micro-hardness, specific cutting energy, and chip morphology are considered under sustainable cooling conditions and compared with the dry condition. The outcome revealed that the N2+MQL reduced the tons of annual coolant consumption attaining smooth surface quality, minimum built-up-edges of chips, and tool wear. Besides, minimum specific cutting energy and surface hardness achieved under N2+MQL among all cooling conditions. This endeavor is peculiar integrating sustainability and machining perspective under advanced cooling techniques for industrial application of Ti-6Al-4V.Öğe Experimental investigation on the effect of dry and multi-jet cryogenic cooling on the machinability and hole accuracy of CFRP composites(Elsevier, 2022) Agrawal, Chetan; Khanna, Navneet; Pimenov, Danil Yu; Wojciechowski, Szymon; Giasin, Khaled; Sarikaya, Murat; Yildirim, Cagri VakkasIn this work, the drilling performance of carbon fibre reinforced plastic (CFRP) composites is analysed in terms of thrust force (F-n), torque (M-z), specific cutting energy (SCE), delamination factor (F-d), and hole quality under dry and cryogenic cooling conditions. An in-house developed multi-jet liquid nitrogen (LN2) delivery setup is used for experimental trials. This LN2 delivery system is retrofitted to an existing machine tool to enable the movement of jets along the axis of the spindle for better reachability of LN2 to the cutting zone during the drilling operation. Experiments are conducted using the full factorial technique considering four levels of spindle rotational speed (N), four levels of feed rate (f(r)), and two cutting conditions i.e., dry and cryogenic cooling. Results show increased F-n up to 35% and decreased M-z up to 24.46% using cryogenic drilling as compared to dry drilling. Moreover, SCE is reduced up to 35% using cryogenic drilling than in dry drilling. Entry F-d is decreased up to 21.55% under cryogenic drilling as compared to dry drilling. At higher N input and lower f(r), the exit F-d can be reduced by up to 9% using cryogenic drilling as compared with dry drilling. In terms of hole quality, cylindricity (CYL) decreased by up to 42.69%, lower deviation in average hole size, and decreased average surface roughness (R-a) up to 20% when using cryogenic drilling. The results show that using the multi-jet cryogenic cooling system provides enhanced composite machinability and sustainability for industrial use. (c) 2022 The Author(s). Published by Elsevier B.V.Öğe In pursuit of sustainability in machining thin walled α-titanium tubes: An industry supported study(Elsevier, 2023) Khanna, Navneet; Kshitij, G.; Solanki, Malhar; Bhatt, Tathya; Patel, Om; Uysal, Alper; Sarikaya, MuratCryogenic machining has emerged as a major sustainable machining techniques especially for difficult-to-cut alloys, including titanium, Inconel alloys in terms of its impact on cost savings for high-value manufacturing projects reduced energy consumption, enhanced worker safety, and eliminating the infrastructure and disposal needed for flood coolants. However, further study is needed to quantify the sustainable elements of machining processes to have a clearer vision for industries to transition from traditional techniques to such advanced techniques. In the currently known literature, the topic of high-speed machining of titanium tubes with thin walls is yet to be explored under advanced cooling technique. The studies on the machinability indicators including tool wear, power consumption etc. are the backbone to the assessment of sustainability aspect of machining. The quantification of sustainability indicators in terms of machining costs and carbon emissions will provide better insights to the industries to maximise their profits and have least negative impacts on the environment. Thus, this study focuses on analyzing sustainability of the machining processes in terms of economic and environmental factors while turning thin walled a-titanium tubes under different cutting environments which include dry, wet and cryogenic machining under two different high cutting speeds of 150 m/min and 200 m/min. The economical aspect comprises the assessment of the different machining costs occurring during the machining. The environmental aspect includes the assessment of carbon emissions occurring during the machining operation. The backbone of the sustainability analysis is the machinability analysis which involves the investigation of power consumption and cutting tool-wear. A comprehensive study of tool wear and total power consumption has been presented to get a better perspective in the machinability of thin walled a-titanium tubes while working in the cryogenic environment in comparison with dry and wet environments. The total machining cost is relatively less (approximately 27%) under cryogenic environment in comparison with a wet environment making it a more economical process. The total emissions of carbon are also found to be lowered (up to 9%) while machining under cryogenic environment in comparison with a wet environment making it a more environmentally friendly process. The cutting tool wear is found to be relatively low (up to 38.68% and 72.24%) under cryogenic environment in comparison with wet and dry environments respectively. Power consumption was compared for the three different environments to have detailed analysis in terms of productivity and sustainability. A significant reduction in total power consumption (up to 19.25%) was observed under cryogenic environment in comparison with wet environment.Öğe Investigation on the effect of hybrid nanofluid in MQL condition in orthogonal turning and a sustainability assessment(Elsevier, 2023) Usluer, Enes; Emiroglu, Ugur; Yapan, Yusuf Furkan; Kshitij, G.; Khanna, Navneet; Sarikaya, Murat; Uysal, AlperThe installation of cost-and energy-efficient chip removal processes is the key point for sustainability. In the literature, many sustainability assessments have been made for minimum quantity lubrication (MQL) and mono nanofluid-assisted MQL (N-MQL) methods, considering energy consumption and costs. However, there are de-ficiencies in the assessment of sustainability in terms of machining cost and carbon emission amount in studies using the hybrid nanofluid MQL (HN-MQL) method. In the presented study, the Taguchi experiment design was established with different cutting conditions (dry, MQL, 0.2% MWCNT nanoparticle reinforced N-MQL, 0.1% MWCNT+0.1% MoS2 nanoparticle reinforced HN-MQL), different cutting speeds (175, 225, 275 and 325 m/ min), and different feed values (0.1, 0.15, 0.2 and 0.25 mm/rev) in the orthogonal turning of S235JR structural steel, and optimum cutting parameters were determined in terms of cutting temperature and cutting forces by ANOVA analysis. This was followed by the sustainability assessment of the experiments conducted to quantify the sustainability aspect of machining in terms of total machining costs and total carbon emissions. While assessing machinability parameters, it was found that the best results out of all the performed experiments for both cutting forces and cutting temperatures were obtained under N-MQL conditions. It was determined that the most effective parameter on cutting force and thrust force was feed with 86.8% and 65% contribution ratios, respectively, and cutting conditions had the most effect on cutting temperature with 93.2% contribution ratio. The total machining cost were lowered by significant amount (up to 76%, 73% and 61% in comparison with dry, MQL and HN-MQL) under N-MQL cutting environment owing to the reduction in energy consumption and better tool life in comparison with other parameters. The overall carbon emissions were also most optimal (better by up to 60% and 37% in comparison with MQL and HN-MQL) under the N-MQL cutting environment in comparison with other cutting environments. The sustainable aspects of the machining process were enhanced more under higher cutting speeds than under lower cutting speeds.Öğe Life cycle assessment of environmentally friendly initiatives for sustainable machining: A short review of current knowledge and a case study(Elsevier, 2022) Khanna, Navneet; Wadhwa, Jwalant; Pitroda, Anjali; Shah, Prassan; Schoop, Julius; Sarikaya, MuratThe establishment of energy and resource-efficient machining processes is key for achieving more sustainable production in the manufacturing industries. However, accomplishing the eco-efficiency goal for machining high strength materials used in the automotive and aerospace industry is challenging, because a trade-off must be achieved between energy consumption and economical productivity. To address this challenge from an ecological perspective, this study focuses on a detailed literature review of Life Cycle Assessment (LCA) analysis made on machining processes considering the comparison of cutting fluid strategies. Along with this, the present study also provides an extensive elucidation regarding the steps required to analyze LCA. Besides, this study aim to analyze LCA analysis in machining processes, and present the case study about macro-level comparative LCA of turning in-house cast AXZ911/10SiC metal matrix composites (MMCs) for three levels of cutting speed (v(c)), longitudinal feed rate (f), and axial depth of cut (a(p)). Each condition was subjected to three different cutting fluid approaches i.e., Dry, Liquid Carbon Dioxide (LCO2), and Liquid Nitrogen (LN2). Streamlined LCA (SLCA) was performed for 18 environmental impact categories using the Ecochain Mobius platform, connected to ReCiPe midpoint (H) and normalized with World (H) method. The findings showed that for all the levels of a(p & nbsp;)and the same cutting strategy, the lower v(c & nbsp;)and lower f result in a higher environmental impact. The comparison of the cutting fluid approach in terms of their correspondent normalized impact score reveals that machining in the cryogenic environment of LN2 with higher v(c) and higher f is the most sustainable and economical approach.Öğe Machinability analysis of nickel-based superalloy Nimonic 90: a comparison between wet and LCO2 as a cryogenic coolant(Springer London Ltd, 2021) Patel, Tej; Khanna, Navneet; Yadav, Sahitya; Shah, Prassan; Sarikaya, Murat; Singh, Dilpreet; Gupta, Munish KumarThe usage of cryogenic fluid is increasing in the machining industries especially to cut the materials having a lower machinability like Nimonic 90, a nickel-based alloy. However, the comparison of flood coolant and LCO2 as a cryogenic fluid based on machining performance has not been found for machining Nimonic 90. In this regard, this study compares LCO2 and conventional mineral oil-based flood coolant on the basis of machining performance while turning Nimonic 90. The effect of turning process parameters (cutting speed (v(c)), feed (f), and depth of cut (a(p))) and cutting fluids has been identified by analyzing machinability indicators like cutting force, flank tool wear, power consumption, surface roughness in terms of R-a, and chip morphology. Increment of 34%, 25%, and 24% in cutting forces has been observed for cryogenic turning using LCO2 in comparison with wet machining when the values of a(p) are 0.75, 0.50, and 0.25 mm, respectively. A decrement of 63% tool wear has been seen in LCO2 cryogenic fluid in contrast to wet machining at higher values of v(c), f, and a(p). The superior surface finish has been found in wet machining, while lesser power consumption was recorded for LCO2 as a cutting fluid. Cryogenic machining provided better chip breakability in comparison with wet machining.Öğe Resource conservation and sustainable development in the metal cutting industry within the framework of the green economy concept: An overview and case study(Elsevier, 2022) Kshitij, G.; Khanna, Navneet; Yildirim, Cagri Vakkas; Dag, Salih; Sarikaya, MuratThe metal cutting industry has an important role in the growth of the global economy. In this industry, while research is made on factors such as cutting tool, cooling/lubrication environments, improved cutting parameters, etc., for increased productivity, serious efforts are also made to obtain environmentally friendly and healthy processes. Based on recent developments in tool materials, cutting speeds have increased significantly in machining operations. However, the increased temperatures with increasing cutting speeds have also reduced productivity and caused resource and product losses. The use of cutting fluids, especially in the machining of superalloys, has a vital task in reducing the problems. However, petroleum-based cutting fluids, which are still frequently used and have an important share in the industry, do not comply with the concept of a green economy due to environmental effects and costs. For this reason, the use of sustainable cutting fluids and optimum pa-rameters in metal cutting industry processes has become a necessity. From this perspective, this study was carried out in two stages. In the first stage, the outputs of the metal cutting industry were examined within the scope of the principles of green economy. In the second stage, a case study was then conducted involving the machining of Inconel 718 and Ti6Al4V alloys at different cutting speeds and under LCO2. In the case study, critical outputs, both from an economic and sustainability point of view, namely cutting tool wear, surface roughness, specific energy consumption, machining costs and carbon emissions are examined. The results obtained in the machining of both materials were compared with each other. Total cost and carbon emissions can be reduced by up to 35% and 7%, respectively, under the appropriate parameter combination and LCO2 cooling conditions.Öğe Resource savings by sustainability assessment and energy modelling methods in mechanical machining process: A critical review(Elsevier Sci Ltd, 2022) Sarikaya, Murat; Gupta, Munish Kumar; Tomaz, Italo; Krolczyk, Grzegorz M.; Khanna, Navneet; Karabulut, Sener; Prakash, ChanderIn machining processes, there are contradictions between high efficiency and environmentally-friendly machining. This indicated that there is a major potential for sustainable machining to both increase efficiency and protect ecological balance. For this, the employment of effective methods has become imperative to reduce resource use. In this way, the use of analysis and optimization tools to select the tool material, cutting parameters, cooling/lubrication conditions, etc., will be a benefit for minimizing waste without sacrificing efficiency. In the literature, researchers have used various methods to reveal the requirements of sustainability. However, reaching the concept of sustainable machining by using one more than technique confuses the readers. Therefore, it was deemed necessary to present and discuss the current methods, models and analyzes in a comprehensive review paper. In this context, this paper reviewed the previously published works, especially focusing on sustainability and energy consumption modeling methods in machining operations. At the end of the study, it was seen that LCA provides a systematic and quantitative view of the system and thus can act as a decision support tool. Moreover, it can give an idea to the manufacturers about the improvement of the process and the areas of innovation. However, the method has several disadvantages such as relatively expensive and specific software, obtaining inventory data, impractical to use, time-consuming and requires large amounts of data. Various mathematical models and algorithms have been developed to deal with the complex situations and offer a more practical use compared to LCA. However, it is difficult to state that clear results have been achieved thanks to these models. It was seen that in complex machining processes, only approximate results can be found with models, which leads to questioning the reliability of the models.Öğe Review on design and development of cryogenic machining setups for heat resistant alloys and composites(Elsevier Sci Ltd, 2021) Khanna, Navneet; Agrawal, Chetan; Pimenov, Danil Yu; Singla, Anil Kumar; Machado, Alisson Rocha; da Silva, Leonardo Rosa Ribeiro; Gupta, Munish KumarCryogenic machining is becoming a sustainable choice due to its extraordinary performance (such as non-toxic and environmentally friendly) superiority to other traditional coolants and lubricants to produce products with superior quality. This paper also critically reviews improvements in designing the cryogenic delivery setup used by researchers for machining low machinability materials like titanium alloys, nickel alloys, ferrous alloys, composites, and other difficult-to-cut materials. It also briefs the economic and sustainable perspective of this state-of-art technology. The aim is to maximize the usage of sustainable cryogenic and hybrid machining technologies in the global manufacturing industry by highlighting their advantages. An overview of in-house developed cryogenic and hybrid machining techniques is presented. Various challenges and future needs related to cryogenic and hybrid-machining techniques are also discussed in the articles. Although remarkable results are obtained with the available literature's delivery methods, there is still no consensus regarding the best cryogenic delivery methods for machining the aforementioned materials. In addition, further hybridization of cryogenic delivery techniques with near dry machining techniques such as minimum quantity lubrication (MQL), electrostatic-MQL (EMQL), and nanofluid based MQL (nMQL) can be beneficial for machinability improvements of difficult-to-machine materials.Öğe Tribological behavior of textured tools in sustainable turning of nickel based super alloy(Elsevier Sci Ltd, 2021) Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Singh, Rupinder; Sarikaya, Murat; Khanna, NavneetIn this research study, textured tools were fabricated and used for machining under different cooling conditions. The most important uniqueness of the work lies in the use of textured tools for machining Inconel-718 under dry, Nitrogen cooling and nanofluids (hBN mixed with minimum quantity lubrication) conditions. In the turning experiments, two different level of cutting speed i.e., 75 and 125 m/min and a constant level for feed rate (0.1 mm/rev) and depth of cut (0.5 mm) were considered. The above three conditions were tested and compared with and without the use of textured tools. The tool wear, surface roughness, cutting temperature, micro-hardness of machined samples and chip morphology were investigated under these subjected conditions and at turning parameters. The results demonstrated that the nanofluids with textured tool provide the superior results in comparison with other cooling conditions. These results establish textured tools as a sustainable alternative to the existing cutting tool technology being used in the manufacturing industry.
