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<p>Sustainability in machining nickel-based superalloys is increasingly critical due to high energy consumption, excessive tool wear, and thermal damage associated with conventional cooling practices. Hastelloy B3 presents severe machining challenges due to its low thermal conductivity and high tool–chip interface temperatures. The specific research gap addressed is the lack of a systematic sustainability-based comparison between external and internal cooling tool-holder architectures under identical MQL and nanofluid MQL conditions. The objective of this work is to evaluate sustainable turning performance of Hastelloy B3 using a newly designed external multi-spray tool holder and an internally cooled top-and-bottom microchannel tool holder. Turning experiments were conducted using dry cutting, coconut oil MQL, and 0.25&#xa0;wt.% Ag nanofluid MQL at cutting speeds of 70–210&#xa0;m/min and feeds of 0.1–0.2&#xa0;mm/rev, while cutting force, cutting temperature, surface roughness, tool wear, and chip characteristics were measured using dynamometry, infrared thermography, profilometry, SEM/EDS, and microhardness testing. Internal nanofluid MQL reduced cutting temperature by 42%, cutting force by 27%, flank wear by 85.2%, and surface roughness by 58.9% compared with dry cutting, while chip shear angle increased to 30.85° and shear strain decreased to 2.21. These results indicate that sustainability is achieved through effective thermo-tribological control enabled by proximity-based internal cooling and nanofluid lubrication. The findings support sustainable tool-holder design strategies for machining nickel-based superalloys, and future work will focus on tool-life modeling and hybrid sustainable cooling systems.</p>

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Sustainability Assessment of Internal Microchannel Cooling with Nanofluid MQL in Hastelloy B3 Turning

  • 期刊论文

  • 发表日期：

    2026年4月10日

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  • T. Murali,
  • V. Elango,
  • Sankar Thangavel,
  • Ratchagaraja Dhairiyasamy

摘要

Sustainability in machining nickel-based superalloys is increasingly critical due to high energy consumption, excessive tool wear, and thermal damage associated with conventional cooling practices. Hastelloy B3 presents severe machining challenges due to its low thermal conductivity and high tool–chip interface temperatures. The specific research gap addressed is the lack of a systematic sustainability-based comparison between external and internal cooling tool-holder architectures under identical MQL and nanofluid MQL conditions. The objective of this work is to evaluate sustainable turning performance of Hastelloy B3 using a newly designed external multi-spray tool holder and an internally cooled top-and-bottom microchannel tool holder. Turning experiments were conducted using dry cutting, coconut oil MQL, and 0.25 wt.% Ag nanofluid MQL at cutting speeds of 70–210 m/min and feeds of 0.1–0.2 mm/rev, while cutting force, cutting temperature, surface roughness, tool wear, and chip characteristics were measured using dynamometry, infrared thermography, profilometry, SEM/EDS, and microhardness testing. Internal nanofluid MQL reduced cutting temperature by 42%, cutting force by 27%, flank wear by 85.2%, and surface roughness by 58.9% compared with dry cutting, while chip shear angle increased to 30.85° and shear strain decreased to 2.21. These results indicate that sustainability is achieved through effective thermo-tribological control enabled by proximity-based internal cooling and nanofluid lubrication. The findings support sustainable tool-holder design strategies for machining nickel-based superalloys, and future work will focus on tool-life modeling and hybrid sustainable cooling systems.