Using the chip-tool thermocouple method to measure the temperature in the milling of Inconel 718 under different lubri-cooling strategies
摘要
Temperature measurement at the chip-tool-workpiece interfaces poses a challenge, particularly in milling, because of its intermittent nature, which limits the effectiveness of conventional temperature measurement methods. The tool-workpiece thermocouple method is frequently used to access this temperature in continuous cutting, like turning, but in intermittent cutting, like milling, its application is rarely reported in the literature. Nickel-based superalloys, such as Inconel 718, exhibit challenging machinability due to their high mechanical strength at elevated temperatures, high resistance to dynamic shear, low thermal diffusivity, and strong tendency to work harden. These characteristics accelerate tool wear and reduce surface integrity, making effective cooling and lubrication techniques essential to mitigate these effects. This study is centered on the successful implementation of the tool-workpiece thermocouple method to provide a rare, direct measurement of average and peak temperatures during the challenging milling of Inconel 718. This approach allowed for a quantitative comparison of five distinct lubri-cooling conditions: dry cutting, compressed air, minimum quantity lubrication (MQL), vortex tube, and flood, under different cutting conditions. The results quantify the significant thermal benefits of lubri-cooling, with flood cooling proving to be the most effective strategy due to its high convection coefficient. Notably, some advanced methods showed limited effectiveness; the vortex tube, despite its sub-zero air jet, failed to provide a statistically significant improvement over the baseline dry cutting condition for average temperatures. Furthermore, while MQL and compressed air offered intermediate temperature reductions, the lubricating effect of MQL provided no additional thermal advantage over compressed air alone. This highlights that the cooling mechanism is more critical than lubrication for thermal control in this application.