Sen Binayak, Murali Krishnam Raju V V, Kumar Raman, Ramachandran T, Jacob Ashwin, Nanda Jajneswar, Singh Gurbhej, Bhowmik Abhijit, Panda Jibitesh Kumar
Centre for Computational Modeling, Chennai Institute of Technology, Chennai, 600069, Tamil Nadu, India.
Department of Mechanical Engineering, Chennai Institute of Technology, Chennai, 600069, Tamil Nadu, India.
Sci Rep. 2025 Jul 1;15(1):21816. doi: 10.1038/s41598-025-07526-0.
The growing significance of superalloys like Hastelloy X, particularly in critical engineering sectors such as aerospace, chemical processing, and selective biomedical equipment (e.g., surgical instruments and medical tooling), underscores the need for advancements in their manufacturing processes. In today's era of advanced manufacturing, it is crucial to develop machining systems that are both environmentally sustainable and cost-effective. To bridge the existing gap between economic, technological, and sustainability aspects in the machining of Hastelloy X, the present research aims to shed light on this critical interplay. Experimental investigations were conducted to evaluate the performance of various cooling techniques, including dry machining, minimum quantity lubrication (MQL), and cryogenic cooling using liquid nitrogen (LN₂) and carbon dioxide (CO₂). The results revealed that cryogenic cooling with LN₂ demonstrated superior performance across technological, sustainability, and economic metrics, outperforming other methods. Specifically, LN₂ cooling during the turning of Hastelloy X led to a reduction in tool wear and surface roughness by 21.11% and 25%, respectively, over dry machining conditions. These findings highlight the potential of advanced lubrication and cooling techniques to enhance sustainable manufacturing practices, reducing resource consumption while improving machining performance, particularly for industries involving difficult-to-machine superalloys.
哈氏合金X等高温合金的重要性日益凸显，尤其在航空航天、化学加工和选择性生物医学设备（如手术器械和医疗工具）等关键工程领域，这突出了改进其制造工艺的必要性。在当今先进制造时代，开发既环保又经济高效的加工系统至关重要。为弥合哈氏合金X加工中经济、技术和可持续性方面的现有差距，本研究旨在阐明这一关键的相互作用。进行了实验研究，以评估各种冷却技术的性能，包括干式加工、微量润滑（MQL）以及使用液氮（LN₂）和二氧化碳（CO₂）的低温冷却。结果表明，使用LN₂的低温冷却在技术、可持续性和经济指标方面均表现出卓越性能，优于其他方法。具体而言，在哈氏合金X车削过程中，与干式加工条件相比，LN₂冷却使刀具磨损和表面粗糙度分别降低了21.11%和25%。这些发现凸显了先进润滑和冷却技术在增强可持续制造实践方面的潜力，在减少资源消耗的同时提高加工性能，特别是对于涉及难加工高温合金的行业。
