Tool life prediction by RSM for cryogenic

milling of inconel 718

Nurul Hayati Binti Abdul Halim
Centre for Engineering Materials and Smart Manufacturing (MERCU), Universiti Kebangsaan Malaysia, Bangi, Malaysia and
Universiti Teknologi MARA, Shah Alam, Malaysia, and
Che Hassan Che Haron, Jaharah A. Ghani and Muammar Faiq Azhar
Centre for Engineering Materials and Smart Manufacturing (MERCU), Universiti Kebangsaan Malaysia, Bangi, Malaysia

Abstract
Purpose – The purpose of this study is to present the tool life optimization of carbide-coated ball nose milling inserts when high-speed milling of
Inconel 718 under cryogenic CO2 condition. The main aims are to analyze the influence level of each cutting parameter on the tool life and to
identify the optimum parameters that can lengthen the tool life to the maximum.
Design/methodology/approach – The experimental layout was designed using Box–Behnken RSM where all parameters were arranged without
combining their highest and lowest values of each factor at the same time. A total of 29 milling experiments were conducted. Then, a statistical
analysis using ANOVA was conducted to identify the relationship between the controlled factors on tool life. After that, a predictive model was
developed to predict the variation of tool life within the predetermined parameters.
Findings – Results from the experimental found that the longest tool life of 22.77 min was achieved at Vc: 120 m/min, fz: 0.2 mm/tooth, ap: 0.5 mm
and ae: 0.2 mm. ANOVA suggests the tool life of 23.4 min can be reached at Vc: 120.06 m/min, fz: 0.15 mm/tooth, ap: 0.66 mm and ae: 0.53 mm. All
four controlled factors have influenced the tool life with the feed rate and radial depth of cut (DOC) as the major contributors. The developed
mathematical model accurately represented the tool life at an average error of 8.2 per cent when compared to the actual and predicted tool life.
Originality/value – These experimental and statistical studies were conducted using Box–Behnken RSM method under cryogenic CO2 condition. It
is a proven well-known method. However, the cooling method used in this study is a new technique and its effects on metal cutting, especially in the
milling process of Inconel 718, has not yet been explored.
Keywords RSM, Cryogenics, Inconel 718, CO2, Tungsten carbide, Milling, Tool life, Cryogenic machining
Paper type Research paper

1. Introduction reported by Patil et al. (2014), (Aramcharoen and Chuan,

Inconel 718 is a nickel-based alloy widely used for fabricating
components operating in aggressive service environment of
heavy industries such as aerospace, marine and petrochemical
plant. In aerospace industry, it is specifically used to produce
the hottest components of turbine engine such as turbine
blades which operate up to 520°C of service temperature. It is
well performed at such environment because of its high heat
and corrosion resistance and high hot hardness and strength
(Ulutan and Ozel, 2011). Moreover, this material also has good
tensile, creep and rupture strength that upsurges its demands in
industries (Ezugwu et al., 2003). However, those superior
properties develop more challenges in terms of its
machinability, particularly when machined at high cutting
speed. For Inconel 718, its high-speed machining begins at
speed of approximately over 50 m/min.
Rapid tool wears that shorten the tool life is among the most
difficulties that need to be tackled when cutting Inconel 718. As
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Industrial Lubrication and Tribology
© Emerald Publishing Limited [ISSN 0036-8792]
[DOI 10.1108/ILT-04-2019-0166]
2014), (Nalbant et al., 2007) and (Hadi et al., 2014), the major
cause of short tool life is the advanced mechanical and chemical
properties of Inconel 718 that increase the mechanical and
thermal loads on the cutting tool. As consequences, the tool
lost its hardness, leading to severe plastic deformation and wear
acceleration. Therefore, proper selections of cutting parameters
and cutting coolant are important as they have significant
influences on tool performances. (Kasim et al., 2013) asserted
that cutting speed, feed rate, and depth of cut provided
significant effect on tool life during high-speed milling Inconel
718 in minimum quantity lubrication (MQL) condition. They
also found that longer tool life can be achieved at lower values
of those parameters. (Abdul Hadi et al., 2016) who also milled
Inconel 718 at high speed found that higher cutting speed
increased the cutting temperature and resulted in severe tool
wear. It is because Inconel 718 tends to harden rapidly at high
Acknowledgement is given to the Government of Malaysia and Universiti
Kebangsaan Malaysia for providing the research fund (grant no:
UKM-DIP-2017-023), tools, material, equipment and support with the
technical solutions.
Received 28 April 2019
Revised 13 May 2019
16 May 2019
16 May 2019
17 May 2019
Accepted 18 May 2019
 Tool life prediction by RSM
Nurul Hayati Binti Abdul Halim et al.
temperature that increases its hardness, as well as its difficulty,
to be machined. Meanwhile (Dilip Jerold and Pradeep Kumar,
2012) and (Machai and Biermann, 2011) found that the
application of cryogenic CO2 offered a better resistance to rake
and flank wear because of the efficient temperature control and
the reducing of coefficient of friction at tool-chip and tool-
workpiece sliding interfaces. Moreover, (Kaynak et al., 2014)
suggested cryogenic machining to be applied at higher speed as
it also generates good surface quality attributed to less tool wear
and thermal distortion.
Cryogenic machining is one of the sustainable machining
practices which use coolant such as liquid nitrogen (LN2) and
carbon dioxide (CO2). The coolant has high cooling capacity
that significantly reduces tool wear rate and leaves zero residues
once it is used (Courbon et al., 2013). Thus, this approach is
particularly attractive because of its advantages that encompass
the measuring of machinability, productivity and elimination of
the contaminations induced by conventionally cutting fluid and
polluted slurries used in machining (Zhang et al., 2018). For
the polluted slurries, novel environment-friendly slurries were
developed to fabricate high performance devices used in
electronics industry, to eliminate the contaminations induced
by them (Zhang et al., 2018, 2019). The machining using the
developed slurries is considered as a sustainable method, which
is a breakthrough and milestone contribution to the traditional
machining and manufacturing. For cryogenic machining, past
researches showed that most of them focused on the application
of LN2 because of its extreme cooling effect (
196°C). But, the
much lower cooling capacity of CO2 (
76°C) is seen to be a
good alternative to the LN2 as it provides less work hardening
effect on the workpiece and becomes the reason for lower
cutting force and tool wear rate when compared to cryogenic
LN2 (Pereira et al., 2015) (Dilip Jerold and Pradeep Kumar,
2012).
In this study, the high speed milling of Inconel 718 was
conducted in cryogenic condition according to machine
parameters designed by Box–Behnken response surface
methodology (RSM). The RSM is a collection of statistical and
mathematical techniques useful for developing, improving, and
optimizing processes (Myers et al., 2009). This technique is
more accurate, economical and faster than the traditional
method such as “trial and error,” “listen to noise” or “based on
vibration” practices (Zhu et al., 2013). Researchers such as
(Kasim et al., 2013), (Badroush et al., 2018) and (Aruna and
Dhanalakshmi, 2012) are among RSM users who have applied
this technique for optimizing and predicting machining
performance. The finding of this research contributes to the
environment-friendly machining performance as opposed to
the traditional machining practices.
2. Methodology
The workpiece is Inconel 718, grade AMS 5663 at measured
hardness of 42 6 2 HRC. For the cutting tool, Sumitomo carbide
coated ball nose milling inserts were used. It is a multi-coated tool
by the alternate layers of TiAlN and AlCrN. The radial rake
angle, axial rake angle, and approach angle were 0°,
3° and 90°,
respectively. The insert was 10 mm in diameter, attached to a
16 mm diameter tool holder. The down-end milling experiments
were performed on a computer numerical controlled (CNC)
Industrial Lubrication and Tribology
milling machine model DMG 635, V Eco. The controlled factors
for the experiment as listed in Table I were controlled at three
levels. A total of 29 experiments were conducted in cryogenic
CO2 condition as in Figure 1. The experimental layout was
designed using Box–Behnken RSM where all parameters were
arranged without combining their highest and lowest value of
each factor at the same time. This is to avoid cutting the material
under extreme conditions which would probably produce
inadequate results (Ferreira et al., 2007). Then, a statistical
analysis using ANOVA was conducted to identify the
relationship between the controlled factors on tool life and to
develop a predictive model to predict the variation of tool life
within the predetermined parameters.
For the cryogenic system, the coolant was the mixture of
liquid and gas CO2 and compressed air with the controlled
pressure of 11 , 6 and 4 bar, respectively. They were mixed
together in a cryogenic cooling system before supplied through
a nozzle at the minimum temperature of approximately
55°C.
The main function of the system is to control the pressure to
reduce the formation of CO2 snow during the phase changes
which happen once the CO2 enters the atmosphere because of
the Joule–Thompson effect (Machai and Biermann, 2011).
This is to optimize the coolant delivery system by supplying the
high pressure coolant directed to the sliding contact between
tool-chip and tool-workpiece interfaces with optimum size of
flow. This is because the CO2 snow causes poor coolant
penetration into the tool tip which will increase cutting
temperature (Dilip Jerold and Pradeep Kumar, 2012). At the
same time, the effect of work hardening which increases the
workpiece hardness could be reduced. Before cutting started,
the flow of coolant was activated until it achieved a stable flow
condition and temperature. The cutting process was
interrupted after every specific pass interval to measure the
growth of maximum flank wear (Vbmax) by using a Mitutoyo
toolmaker’s microscope. The cutting process was then
continued using the same insert until the Vbmax reached
Table I Cutting parameters and their levels of control
Level of control parameters
Control parameters
1 0 1
Cutting speed, Vc (m/min) 170 190 210
Feed rate, fz (mm/tooth) 0.15 0.2 0.25
Axial depth of cut, ap (mm) 0.3 0.5 0.7
Radial depth of cut, ae (mm) 0.2 0.4 0.6
Figure 1 Experimental setup with cryogenic CO2 delivery
 Tool life prediction by RSM Industrial Lubrication and Tribology
Nurul Hayati Binti Abdul Halim et al.

0.2 mm. This was to avoid the catastrophic failure due to
excessive temperature and friction induced by the worn tool
which could reduce the accuracy of the predicted model. This
approach was comparable with researchers such as (Grzesik
et al., 2017) and (Pereira et al., 2017).
3. Results and optimization
3.1 Tool life from experimental results
Table II shows 29 experimental layouts with the experimental
and predicted tool life results. Based on the experimental
results, the longest and shortest tool lives were 22.77 min and
3.17 min, respectively, both obtained at experiment 9 and 24.
3.2 Statistical analysis using ANOVA
The tool life results obtained were used as main input to the
Design Expert V6 software to run the statistical ANOVA.
Based on the ANOVA result as in Table III, the F-Value of the
model was 72.72 and the Prob>F was obviously smaller than
0.05. This implies that the model is significant. By arranging
the F values in a descending order, the Box–Behnken quadratic
model revealed factors B, D, A, C, BD, D2, AC, A2 and AB
which represented fz, ae, Vc, ap, fzae, ae2, Vcap, Vc2 and Vcfz,
as the significant model terms in the model. All of them had a
significant effect on the tools life with the major influence
coming from fz and ae. Table III also shows that the lack of fit
was 0.0717 which indicated it was not significant. Thus, the
model was adequate and fit for predicting the tool life.
Furthermore, the determination coefficient (R2) of the model
was 0.9668, which specified that the model adequately
represented the real relationship between the control factors.
An adequate precision of 32.183 which was greater than 4
indicated an adequate signal, which was considered desirable.
The interaction between control factors on the tool life was
analysed using 3 D surface model graphs as shown in Figure 2.
These graphs were fully developed by the software using the
main inputs which were the experimental results. Figure 2a
shows the interaction between fz and ae. Both approaches
which were done by increasing the ae at minimum fz or by
increasing the fz at minimum ae would extend the tool life.
Based on the interaction between Vc and ap as shown in
Figure 2b, the longest tool life could be achieved either by
increasing the Vc at the lowest ap or increasing the ap when Vc
is at the minimum value. For interaction between Vc and fz as
in Figure 2c, it recommends that the lowest Vc and fz should be
applied to lengthen the tool life to the longest. However,
increasing the fz at any value of Vc will reduce the tool life. The
steepest skewness of fz showed its higher influence on the tool
performance. In general, the tool life can be lengthened by
reducing all the single factors values. The increase of fz and ap

Table II Tool life results from actual and predicted

Tool life (min)
No. Vc (m/min) fz (mm/tooth) ap (mm) ae (mm) Actual Predicted Error (%)
1 120 0.15 0.50 0.40 20.91 20.57 1.62
2 140 0.15 0.50 0.40 10.26 11.31 10.24
3 120 0.25 0.50 0.40 11.39 11.11 2.48
4 140 0.25 0.50 0.40 6.00 7.11 18.43
5 130 0.20 0.30 0.20 17.63 19.30 9.47
6 130 0.20 0.70 0.20 13.47 13.36 0.82
7 130 0.20 0.30 0.60 12.8 12.63 1.36
8 130 0.20 0.70 0.60 7.05 6.69 5.16
9 120 0.20 0.50 0.20 22.77 22.44 1.46
10 140 0.20 0.50 0.20 16.90 15.81 6.48
11 120 0.20 0.50 0.60 14.15 15.76 11.40
12 140 0.20 0.50 0.60 7.85 9.13 16.33
13 130 0.15 0.30 0.40 17.58 16.12 8.31
14 130 0.25 0.30 0.40 9.41 9.28 1.33
15 130 0.15 0.70 0.40 9.43 10.18 7.95
16 130 0.25 0.70 0.40 3.77 3.34 11.28
17 120 0.20 0.30 0.40 15.09 14.74 2.29
18 140 0.20 0.30 0.40 17.43 16.24 6.81
19 120 0.20 0.70 0.40 17.25 16.93 1.83
20 140 0.20 0.70 0.40 3.33 2.17 34.74
21 130 0.15 0.50 0.20 15.43 15.43 0.01
22 130 0.25 0.50 0.20 17.36 17.23 0.77
23 130 0.15 0.50 0.60 18.50 17.39 6.01
24 130 0.25 0.50 0.60 3.17 1.92 39.32
25 130 0.20 0.50 0.40 8.91 9.73 9.23
26 130 0.20 0.50 0.40 9.13 9.73 6.59
27 130 0.20 0.50 0.40 9.60 9.73 1.38
28 130 0.20 0.50 0.40 8.46 9.73 15.04
29 130 0.20 0.50 0.40 9.83 9.73 1.00
 Tool life prediction by RSM Industrial Lubrication and Tribology
Nurul Hayati Binti Abdul Halim et al.

Table III ANOVA Table for tool life

Source Sum of squares DF Mean square F value Prob > F
Model 771.07 9 85.67 72.72 < 0.0001 Significant
A-cutting speed (Vc) 131.94 1 131.94 111.98 < 0.0001
B-feed rate (fz) 140.15 1 140.15 118.95 < 0.0001
C-axial depth of cut (ap) 105.85 1 105.85 89.84 < 0.0001
D-radial depth of cut (ae) 133.60 1 133.60 113.39 < 0.0001
A2 53.80 1 53.80 45.66 < 0.0001
D2 73.38 1 73.38 62.28 < 0.0001
AB 6.92 1 6.92 5.87 0.0256
AC 66.10 1 66.10 56.10 < 0.0001
BD 74.48 1 74.48 63.21 < 0.0001
Residual 22.39 19 1.18
Lack of fit 21.19 15 1.41 4.74 0.0717 Not significant
R-squared 0.9718
Adj R-squared 0.9584
Pred R-squared 0.9228
Adeq precision 32.183

Figure 2 Interaction between (a) feed rate and radial depth of cut (DOC), (b) cutting speed and axial DOC and (c) cutting speed and feed rate

increased the volume of material removal by the tool (Alauddin
et al., 1998). Thus, more cutting force is required by the tool to
produce chips. Bigger and thicker sizes of chips increase the
friction force at the tool-chip interface which then weakens the
tool and reduces its wear resistant. Meanwhile, the increase of
ae widened the friction area between the tool and machined
surface and the increase of Vc was parallel to the increase of
cutting temperature. These conditions resulted with rapid tool
wear that retarded the cutting process in the form of notching
and flaking.
 Tool life prediction by RSM
Nurul Hayati Binti Abdul Halim et al.
3.3 Development and validation of the second-order
model using RSM
Second order model equation for the tool life was established
based on the experimental results by the software using Box–
Behnken RSM design as in equation (1) below:
Tool life ¼ 252:92 – 2:57Vc
145:6fz 1 178:24ap
1 4:40ae 1 0:000698Vc2 1 81:52ae2
1 1:32Vc:fz
1:02Vc:ap
431:5fz:ae
The model was then used to calculate the predicted tool life.
Based on the comparison results between the predicted and
actual tool life as shown in Table II, the errors ranged from 0.01
per cent to 39.32 per cent and the average error was 8.2 per
cent. According to Hills and Trucano (1999), the optimization
model can be considered valid and acceptable when the error
was less than 10 per cent.
To validate the adequacy of the mathematical model, the
diagnostic plots of the predicted vs. actual and the outlier T as
per Figure 3a and 3b were analysed. Both plots proved that the
residuals followed a normal distribution and fit the data well. As
per Figure 3(a), all actual and predicted points fall close to the
straight line, which means that the errors were normally
Figure 3 (a) The diagnostic plots of the predicted vs actual, (b) outlier T
Figure 4 Ramps view of optimum parameters and predicted tool life
Industrial Lubrication and Tribology
distributed. Meanwhile, in Figure 3(b), all data were within the
limits, which showed no obvious pattern and unusual structure
in the model.
3.4 Optimization of tool life
By using the software, the optimum parameters were
automatically extracted by the ANOVA. It suggests the
optimum result can be reached at Vc: 120.06 m/min, fz:
0.15 mm/tooth, ap: 0.66 mm and ae: 0.53 mm to obtain a tool
(1) life of 23.4 min. The ramp view in Figure 4 clearly indicated the
point of optimum parameter and the longest tool life in the set
parameters. This predicted tool life was longer than the longest
tool life which was achieved through the experimental works.
4. Conclusion
In this study, the Box–Behnken RSM was systematically
applied to improve the tool life of carbide coated ball nose
milling inserts in high-speed milling of Inconel 718 under
cryogenic CO2 condition. Results from the experimental found
that the longest tool life of 22.77 min was achieved at Vc:
120 m/min, fz: 0.2 mm/tooth, ap: 0.5 mm and ae: 0.2 mm.
However, ANOVA suggests the tool life of 23.4 min can be
reached at Vc: 120.06 m/min, fz: 0.15 mm/tooth, ap: 0.66 mm
 Tool life prediction by RSM
Nurul Hayati Binti Abdul Halim et al.
and ae: 0.53 mm. All four controlled factors have influenced the
tool life with the feed rate and radial DOC as the major
contributors. For interaction between factors, the main
influencer was the interaction between feed rate and radial
DOC. It was also found that the developed mathematical
model accurately represented the tool life at an average error of
8.2 per cent when compared to the actual and predicted tool
life. This shows that the model is adequate for predicting the
tool life values within the range of predetermined parameters in
the cryogenic CO2 environment.
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About the authors
Nurul Hayati Binti Abdul Halim is a PhD student in the
field of mechanical engineering at the Faculty of Engineering
and Built Environment, Universiti Kebangsaan Malaysia. She
received an MSc from Universiti Teknologi MARA in the field
of Advanced Manufacturing. Her current research interests
are cryogenic machining of CNC milling process (metal
cutting), tool wear monitoring, chip morphology and design of
experiment using response surface methodology.
Nurul Hayati Binti Abdul Halim is the corresponding author
and can be contacted at: nrulhayati@gmail.com
Che Hassan Che Haron is a Professor in the Department of
Mechanical and Material Engineering, Faculty of Engineering
and Built Environment at Universiti Kebangsaan Malaysia.
His research interests lie in manufacturing and productions
engineering machining, cutting tool technology, tribology and
machinability of difficult-to-machine materials such as
titanium and Inconel 718 and wear of cutting tools and chip
 Tool life prediction by RSM Industrial Lubrication and Tribology
Nurul Hayati Binti Abdul Halim et al.

formation and the application of response
methodology for design of experiment.
Jaharah A. Ghani is a Professor in the Department of
Mechanical and Material Engineering, Faculty of
Engineering and Built Environment at Universiti
surface Kebangsaan Malaysia. Her research interests are tribology,
machining (metal cutting), detailed studies of cutting tools
development, wear of cutting tools (including tool wear
monitoring) and chip formation and the extensive use of
Taguchi’s design of experiment.

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