Evaluating the effects of nano-fluids based MQL milling of IN718 associated to sustainable productions

The aeronautical industry is constantly striving for goals related to lesser production/maintenance time and cost. In this regard, aero-engines made up of Nickel-based alloy are preferred for high performance to improve the burning efficiency. However, the processing of the Nickel-based alloys remain challenging in manufacturing industry with the aim of sustainable production. This research investigated the manufacturing progress of face milling of Inconel 718 by using two different lubrication conditions; minimum quantity lubrication (MQL) and nanofluids based minimum quantity lubrication (NF-MQL). A high degree of sustainability was achieved through increasing productivity (material removal rate) and quality (surface roughness) enhancement while minimizing the power and temperature. The impacts of four most influencing parameters including feed rate, speed, flow rate and depth of cut were investigated on sustainable production performance measures. Empirical models of surface roughness, temperature, material removal rate and power were developed using response surface methodology. Analysis of the developed empirical models and validation were executed through analysis of variance and confirmatory experiments results. Finally, a multi objective optimization was implemented to attain maximum sustainability effect by generating a compromise between lowest surface roughness and cost, and highest material removal rate. The results revealed that the depth of cut is the most significant process parameter for both lubrication environments. The results show the NF-MQL as the better alternative which resulted in 20.1%, 14.7% and 13.3% percentage reduction for surface roughness, temperature and power, respectively. Furthermore, the results revealed that NF-MQL resulted in better desirability achievement (71.3%) as compared to MQL (70.1%). [Display omitted] •Machinability assessment through face milling of IN718 is carried out under two lubrication conditions.•Water-based lubrication conditions (MQL, NF-MQL) are evaluated to achieve environmentally conscious processing.•Roughness, tool-workpiece interaction temperature, material removal rate and power consumption were investigated.•Surface morphology is studied with respect to physical phenomenon involved.•The use of NF-MQL achieved surface roughness as low as 0.10 μm with superior sustainability rating.