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<p>This study evaluates the effect of tool texturing on the machinability of KhN67VMTYu, a nickel-based superalloy that finds usage in the manufacturing of sub-assemblies of turbines, oxidizers, and fuel pumps in aerospace vehicles. Channel-shaped textured patterns on tools contributed to a maximum increase in tool life by 58.33%, and substantial reductions in surface roughness (48.60%) and cutting forces (22.35%) compared to conventional tools. These improvements were observed when the experimental trials were performed using a 2<sup>3</sup>-full factorial design at sustainable dry machining conditions. The enhanced heat dissipation features and lower contact stress contributed to reduced crater depressions and micro-chipping formations during the initial machining stages across the textured tools. However, the accumulation of chip debris in the textured cavities led to a re-emergence of frictional interactions in later stages, slightly diminishing the effectiveness of the textures. Despite this, the textured tools performed better in countering the thermal softening and strain-hardening effects, demonstrating superior performance over conventional tools in machining KhN67VMTYu.</p>

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Sustainable Machining of KhN67VMTYu Using Textured Tools: Insights into Tool Wear, Forces, and Surface Roughness Analysis

  • 期刊论文

  • 发表日期：

    2025年6月16日

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  • Allan George,
  • P. B. Dhanish,
  • Jose Mathew

摘要

This study evaluates the effect of tool texturing on the machinability of KhN67VMTYu, a nickel-based superalloy that finds usage in the manufacturing of sub-assemblies of turbines, oxidizers, and fuel pumps in aerospace vehicles. Channel-shaped textured patterns on tools contributed to a maximum increase in tool life by 58.33%, and substantial reductions in surface roughness (48.60%) and cutting forces (22.35%) compared to conventional tools. These improvements were observed when the experimental trials were performed using a 23-full factorial design at sustainable dry machining conditions. The enhanced heat dissipation features and lower contact stress contributed to reduced crater depressions and micro-chipping formations during the initial machining stages across the textured tools. However, the accumulation of chip debris in the textured cavities led to a re-emergence of frictional interactions in later stages, slightly diminishing the effectiveness of the textures. Despite this, the textured tools performed better in countering the thermal softening and strain-hardening effects, demonstrating superior performance over conventional tools in machining KhN67VMTYu.