Experimental investigation and performance optimization during machining of Hastelloy C-276 using green lubricants

Abstract

Smart manufacturing is the demand of industry 4.0, in which the mass production of difficult-to-cut materials is of great concern to fulfil the goal of sustainable machining. Presently, the machining of superalloy is of upmost interest because of its wide application. However, the limited data on the turning of Hastelloy C-276 highlights its challenges during processing. Hence, the machining performance of superalloy considering surface quality, thermal aspects and chip reduction coefficient was examined with minimum quantity lubrication of several oils to address the sustainable development goal (SDG-12). The output responses were optimized through response surface methodology along with analysis of variance. The research exhibited that the output responses were dominated by cutting speed and feed rate having a percentage benefaction of 24.26% and 60%, respectively, whilst the depth of cut and lubricant type have an influence of 10–12%. No major difference in temperature range was reported during the different lubrication conditions. However, a substantial variation in surface roughness and the chip reduction coefficient was revealed. The percentage error evaluated in surface roughness, temperature and chip reduction coefficient was less than 5%, along with an overall desirability of 0.88, describing the usefulness of the model used. The SEM micrograph indicated a loss of coating, nose and flank wear during all lubrication conditions. Lastly, incorporating a circular economy has reduced the economic, ecological and environmental burden.