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USE OF VORTEX TUBE AIR COOLING DURING MACHINING OF INCONEL 718:

EXPERIMENTAL INVESTIGATION AND MODELING STUDIES

Article in Journal of Mechanical Engineering Research and Developments · August 2019

DOI: 10.26480/jmerd.05.2019.127.131

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 Journal of Mechanical Engineering Research and Developments (JMERD) 42(5) (2019) 127-131

Journal of Mechanical Engineering Research and

Developments (JMERD)
DOI : http://doi.org/10.26480/jmerd.05.2019.127.131
ISSN: 1024-1752
CODEN : JERDFO

RESEARCH ARTICLE
USE OF VORTEX TUBE AIR COOLING DURING MACHINING OF INCONEL 718:
EXPERIMENTAL INVESTIGATION AND MODELING STUDIES
Mr. Bhaskara P Achar, Mr. Grynal D’Mello, Dr. Srinivasa Pai P*, Mr. Gururaj K.

Dept. of Mechanical Engg., NMAM Institute of Technology, Nitte-574 110, Karnataka State, India
*Corresponding Author Email: srinivasapai@nitte.edu.in

This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in
any medium, provided the original work is properly cited.

ARTICLE DETAILS ABSTRACT

Article History:
Received 15 July 2019
Accepted 21 August 2019
Available online 29 August 2019
Among Nickel based super alloys, Inconel 718 is a most widely used alloy, due to its superior properties like high
temperature resistance, corrosion resistance, creep resistance, good mechanical properties etc. But, machining this
alloy is a challenge even today because of its high temperature strength, hot hardness, wear resistance and work
hardening and is considered as a ‘difficult-to-machine’ material. To overcome these problems, lubrication and
cooling is an effective method and there have been several research studies aimed to reduce the machinability
problems considering different cooling methods. But these methods have their own disadvantages and to overcome
these and to support ‘sustainability’, air cooling is being adopted in a big way by machining industries. Thus, this
research work focusses to experimentally investigate the effect of air cooling during turning of Inconel 718 using
uncoated carbide inserts. The machinability is being evaluated in terms of cutting tool temperature, tool wear,
surface roughness and cutting tool vibrations. Experiments are conducted at different speeds and feeds and results
have been compared with dry machining. Further Random forest regression, a statistical technique is used to model
surface roughness using data collected from air cooled experiments. It is found to be effective in modeling surface
roughness, with a prediction accuracy of more than 89 % for Ra.

KEYWORDS

Inconel-718, vortex tube air cooling, dry machining, cutting tool temperature, surface roughness.

1. INTRODUCTION
Super alloys of Nickel are having a vast usage in aerospace industry and
more than 75 % by weight of aircraft and more than 50 % by weight of jet
engine parts are made of these alloys. Inconel 718 is widely used in a
variety of applications due to their desirable properties like high corrosion
resistance, strength to weight ratio, creep strength, etc. [1]. These alloys
are mainly used in airplane engine parts (e.g. turbine discs, compressor
discs, shafts, rings, casings and blades), biomedical implants (joints),
reciprocating engines, metal processing, steam turbines, chemical and
petrochemical industries, space vehicles, heat treating equipment, gas
turbines, coal gasification and liquefaction plants and marine engine parts
[2].
The machinability of Nickel based alloys is poor due to its metallurgical
condition. Due to its austenitic structure, work hardening occurs rapidly
while machining. This affects the machinability further during machining
operations and can damage the work piece surface. The presence of phases
like carbides, nitrides, oxides, silicates etc., has a tendency to cause tool
wear and large amount of heat is generated during machining. This is
because they have low thermal conductivity and thermal diffusivity [3].
They also have a tendency to promote formation of built-up edge (BUE),
which can also reduce tool life and lead to poor surface finish [1]. A
previous study discussed the machinability of Ni based alloys considering
different techniques of cooling including cryogenic cooling, cryogenic
treatment of tool and a hybrid technique of cryogenic cooling of tool with
heating of work piece. There was an improvement in tool life and surface
quality [1]. To reduce the problem of tool wear, tool temperature, and
reduction in surface roughness etc., researchers are exploring different
alternatives like development of better tool materials and cutting
geometries, more resistant tool coating and use of new lubrication
strategies [4]. Among these strategies, the focus is more on use of alternate
lubrication strategies and include flood cooling, cryogenic cooling,
minimum quantity lubrication (MQL), use of solid lubricants etc. [5]. The
use of cutting fluids in flood lubrication, is the most common cooling and
lubrication technique used by industries. But due to stringent
environmental laws, there is a need felt to replace this cooling method
with other alternatives. Cutting fluids constitute a major cost component
in the total machining cost, it is a source of health problems like irritation
to skin, lung, eyes, nose and throat and cause of dermatitis, acne,
hypersensitivity, pneumonitis, asthma, irritation of the upper respiratory
tract and various type of cancers. They also cause problems of disposal.
Hence other methods of coolant use like MQL, solid lubricants, better
design of nozzles, cryogenic cooling etc. are being investigated [6]. Further
use of dry machining can reduce all these problems and have advantages
like no environmental pollution, reduced disposal and cleaning costs and
no health hazard to workers. But can cause increase in the cutting tool
temperature and thereby increase tool wear and damage the surface
finish. The other sustainable cooling strategies include use of air cooling,
which can support sustainable initiatives in a big way, as air is readily
available. Further efforts are on in using hybrid cooling strategies like MQL
and compressed cold air, which can complement each other overcoming
the limitations of each [7].
Studied the heat transfer mechanism in MQL technique during grinding of
CK45 soft steel using simulation [8]. To further improve the cooling ability
of MQL, a simple and inexpensive vortex tube was used. The results
revealed that 95 % heat is removed by compressed air. Also, air pressure
is important than temperature in cooling process. There is a significant
reduction in tangential grinding force and friction coefficient. But surface
finish is poor at optimum condition, which has the highest heat transfer
coefficient [8]. A study made an effort to compare specific energy
consumption during turning of Inconel 718 using dry, vortex-tube chilled
air and nanolubricants enhanced MQL using coated carbide tool at
different speed, feeds and constant depth of cut [9]. There was a marginal
difference in the specific energy consumption between the three methods.
The best results were obtained for MQL [9]. Developed mathematical
models for analyzing the effects of air-cooling during machining of Ti-6Al-

Cite The Article: Mr. Bhaskara P Achar, Mr. Grynal D’Mello, Dr. Srinivasa Pai P, Mr. Gururaj K. (2019). Use of vortex tube air cooling during machining
of Inconel 718: Experimental Investigation and Modeling studies. Journal of Mechanical Engineering Research and Developments, 42(5) : 127-131.
 Journal of Mechanical Engineering Research and Developments (JMERD) 42(5) (2019) 127-131

4V alloy during hard turning [10]. The use of air cooling, has better instrument (Talysurf, make TAYLOR & HOBSON). Figure 1 shows the
penetration to the cutting zone, reduces the cutting temperature, tool experimental setup.
wear and improves surface roughness. The cutting parameters have
similar effect on the machining of the alloy for both dry and air cooling
[10]. Compared variety of cooling methods in turning of Inconel 718 [4].
Use of cold air produced better results, when compared to dry cutting, but
underperformed compared to use of oils. Cryogenic cooling resulted in
less tool wear, when compared to use of emulsion, cold air and dry
machining [4]. An investigated the effect of air cooling on turning of steel
St 40 [11]. It was found that overhead jet cooling was more effective in
reducing tool temperature than interface jet cooling. There was a
significant reduction in nose wear. It resulted in better chip formation
control and lower temperatures leading to better surface finish [11]. A
studied the effect of chilled air coolant during machining of 2205 duplex
stainless steel on surface roughness and tool wear [5]. The study was
carried out on a turning machine using coated carbide tools at constant
speed, feed and depth of cut. Further comparison was done between
conventional cooling and air cooling. Surface roughness was lower in case Figure 1: Experimental set up
of air cooling, whereas tool wear was lower in case of conventional cooling
[5]. Kadam and Pawde (2017) studied surface quality in high speed 3. RESULTS AND DISCUSSION
turning of Inconel 718 using coated carbide tools at constant cutting
In this section the influence of vortex tube cooling technique on surface
speed, feed and depth of cut under dry condition, use of water vapor and
roughness, cutting tool temperature, flank wear, and cutting tool
chilled air. Use of water vapor resulted in better surface finish. Use of
vibrations during machining of Inconel 718 at different speeds for
chilled air resulted in poor surface finish [12]. Arruda and Brandao (2017)
different feed rates is discussed.
performed turning operations on API 5L X70 steel seamless tubular
workpieces. The study was focused on tool wear and surface finish using
dry and cold air system. Use of cold air system resulted in increase in tool
life. The influence on wear and surface finish was dependent on the cutting
speed [13]. An investigated the machinability of titanium (grade II alloy)
using CBN tool under MQL conditions [14]. The process parameters varied
include feed rate, cutting speed, and side cutting edge angle. Response
surface methodology (RSM) was used to model cutting forces, power
consumption and tool wear. MQL is an economic and effective option,
when compared to dry and flood cooling. The forces generated, tool wear
and power consumption depended on the cutting conditions. The optimal
conditions for minimal tool wear, cutting force and power consumption
was 200 m/min, 0.10 mm/rev and 90° [14].
(a)
Based on this literature review, it is clear that there have been very few
studies regarding use of air cooling during turning of Inconel 718. Further
very few researchers have investigated the use of random forest for
modeling and prediction of surface roughness.

This study aims to investigate the use of air cooling during turning
operations on Inconel 718 at different cutting speed and feed rate. The
machinability has been evaluated in terms of tool wear, surface roughness,
cutting tool vibrations and cutting tool temperature. Further comparison
of results with dry machining has been carried out. Random forest, a
relatively new machine learning algorithm has been used to model surface
roughness and more than 77 % prediction accuracy has been achieved.
(b)
2. EXPERIMENTAL PROCEDURE
Figure 2: Variation in flank wear with number of machining passes for
Turning experiments were carried out at different cutting speed and feeds different cutting speeds at (a) 0.1 mm/rev and (b) 0.2 mm/rev
on Inconel 718 bars. The dimension of the bar is 50 mm in diameter and
200 mm in length. Table 1 gives the chemical composition of alloy. Tool wear achieved is maximum at the highest speed of 80 m/min for all
the feed rates investigated and further for feed rate of 0.1 mm/rev, it
Table 1: Chemical composition of Inconel 718 reached 0.4 mm (limiting value) in only two machining passes as shown in
Figure 2a. At higher feed rates, BUE and chip weld was observed,
particularly at lower speed [15]. Cutting speed was the dominant
parameter affecting tool wear while machining super alloys including
Inconel 718 [2]. The effect of feed rate is inverse to that of speed i.e., flank
Experimentations were conducted on a CNC Turning Centre (HMT Stallion
wear was maximum for minimum feed rate as shown in Figure 2 a).
100SU) using uncoated carbide inserts (883 with MR4 chip breaker,
supplier M/s SECO tools). The cold air is supplied using vortex tube
(#3208, make EXAIR) which is 80 % of the total capacity. The experiments
are conducted at different speeds (40, 60 & 80 m/min) and feed rates (0.1,
0.15 & 0.3 mm/rev) at a common depth of cut of 0.5 mm.

Temperature is measured online using noncontact, IR Thermometer

(#42512, make EXTECH) and vibration is measured online using Isotron
Model 65 triple axis accelerometer with necessary hardware in three
directions. Tool wear is measured offline using Tool maker’s microscope
(TM 505, make MITUTOYO) and the criteria is VBmax and surface
roughness is measured offline at three points on the circumference of the
workpiece and the average value is considered using stylus type
(a)

Cite The Article: Mr. Bhaskara P Achar, Mr. Grynal D’Mello, Dr. Srinivasa Pai P, Mr. Gururaj K. (2019). Use of vortex tube air cooling during machining
of Inconel 718: Experimental Investigation and Modeling studies. Journal of Mechanical Engineering Research and Developments, 42(5) : 127-131.
 Journal of Mechanical Engineering Research and Developments (JMERD) 42(5) (2019) 127-131

vibration amplitude as shown in Fig. 5 a) and b). At 0.1 mm/rev, as

reported earlier, for highest speed of 80 m/min, there was a drop-in
vibration amplitude. At 0.2 mm/rev, as the cutting speed increased, the
increase in vibration amplitude is very clear. Again, at the highest speed,
there is a drop in vibration amplitude at the instant of maximum tool wear.
The overall observation is there is a decrease in vibration amplitude at the
end of tool life.

(b)

Figure 3: Variation of cutting tool temperature with number of

machining passes for different cutting speeds at (a) 0.1 mm/rev and (b)
0.2 mm/rev

Figure 3. illustrates that at lower feed rate, increase in cutting speed led to
an increase in temperature. As the feed rate increased, there was a
decrease in the cutting tool temperature. This has a correlation with (a)
variation in flank wear with feed rate. Feed rate has an inverse
relationship with cutting tool temperature.

(b)

(a) Figure 5: Variation of cutting tool vibrations with number of machining

passes for different cutting speeds at (a) 0.1 mm/rev and (b) 0.2 mm/rev

3.1 Comparison of Vortex Tube Air Cooling with Dry Machining:

Higher cutting speed and feed rate condition of 80m/min and
0.2mm/rev have been considered to find out the effect of vortex tube
cooling assisted machining for comparison with dry machining.

(b)

Figure 4: Variation of surface roughness with number of machining

passes for different cutting speeds at (a) 0.1 mm/rev and (b) 0.2 mm/rev
(a) (b)
The surface roughness has been evaluated considering Ra (arithmetic
average). This is one of the widely used parameter and important indicator
of the surface quality. Fig. 4 a) describes that, for lower feed rate, as the
cutting speed increased, there was a deterioration of the surface finish,
with increase in surface roughness [2]. This behavior was also observed at
the highest feed rate of 0.2 mm/rev. as shown in Fig. 4 b). Further at 0.1
mm/rev, at the highest speed of 80 m/min, there was a sudden drop in
surface roughness for the second pass, corresponding to maximum tool
wear. This could be due to smoothened nose region of the tool due to
increased wear, which decreased the surface roughness. Thus, the effect of
(c) (d)
feed rate on surface roughness also depends on the cutting speed. At
individual feed rates, the increase in surface roughness is due to the Figure 6: Comparison of variations in a) Surface roughness, b) Flank
increase in flank wear. Hence feed rate has a dominant effect on the surface wear, c) Tool temperature and d) Tool vibrations in machining of Inconel
roughness. Decreased surface roughness at higher cutting speeds for a 718 under dry and vortex cooling conditions at 80m/min cutting speed.
given feed rate was due to less adhesion resulting in reduction of
Vortex cooling technique is found to be having a good influence in
formation of BUE [2]. improvement of surface roughness when compared to dry cutting as
shown in Fig.6 a) for earlier machining passes. However, it is found to be
Cutting tool vibrations are commonly generated while machining metals,
not effective in improving surface finish at the end of tool life. It can be
but it is more significant when machining difficult to machine materials observed in Fig 6 b) that, high tool flank wear has occurred in the initial
due to their low modulus of elasticity. Among the three components of stage during vortex cooling assisted machining, but later it is found to be
cutting tool vibrations measured namely Vx (depth of cut), Vy (cutting lesser than that for dry machining conditions. Also, it can be noted that
speed) and Vz (feed) directions, Vy is dominant and has been considered rate of tool wear is higher in dry machining. The reduced tool wear rate
for further evaluation. The RMS value of vibrations has been considered. in vortex tube air cooling system can be attributed to reduced cutting tool
As the speed and feed rate increases, there is an increasing trend in the temperature. The cutting tool temperature values are found to be greatly

Cite The Article: Mr. Bhaskara P Achar, Mr. Grynal D’Mello, Dr. Srinivasa Pai P, Mr. Gururaj K. (2019). Use of vortex tube air cooling during machining
of Inconel 718: Experimental Investigation and Modeling studies. Journal of Mechanical Engineering Research and Developments, 42(5) : 127-131.
 Journal of Mechanical Engineering Research and Developments (JMERD) 42(5) (2019) 127-131
lower than that of dry machining condition for every machining cut as
shown in Fig. 6 c), as the cold air effectively carries away the heat
produced at the cutting zone. The tool vibrations are found to be less with
lower values in dry machining than vortex tube air cooling assisted
machining. It was observed from the experimental results that; vortex tube
cold air assisted machining reduced the tool temperature and flank wear by
39% and improved surface finish by 21% but tool vibrations were found
to be increased.
(a) (b)
(c) (d)
Figure 7: Comparison of variations in a) Surface roughness (Ra), b) Flank
wear, c) Tool temperature and d) Tool vibrations in machining of Inconel
718 under dry and vortex cooling conditions at 40m/min cutting speed.
Experimental results have shown that vortex tube cooling has negative
influence on flank wear and surface roughness during low speed
machining at 40m/min as shown in Fig. 7 a) and b). Dry machining gave
better surface roughness values and flank wear values increased for
vortex tube air cooling. Cooling method doesn’t seem to have influence on
tool life by reducing flank wear and hence there is no decrease in surface
roughness as well, instead it has negative effect. However, cutting
temperature is found to be lower in each machining pass than that for dry
machining as shown in Fig. 7 c) and is due to the heat carried away by the
vortex cold air jet from the vicinity of tool chip interface. Tool vibrations
have been found to be lower during vortex cooling assisted machining
than dry machining. Irrespective of the machining speed the cutting
vibrations are mostly same during all the passes when using cold air jet,
whereas dry machining tool vibrations show variations as depicted in Fig.
7 d) and decrease at the end of tool life.
4. RANDOM FOREST REGRESSION (RFR)
Random forest is a machine learning technique developed by Breiman
and has been used for classification, regression and other tasks, which is
based on tree predictors in order to produce the output by using the
nearest neighbor predictor to improve the prediction performance [16].
Every tree grows as an individual tree in the group, in accordance to the
random vector. The algorithm of execution is as follows.
1. Draw ‘t’ bootstrap samples from the original data.
2. For each of the bootstrap samples, grow a regression tree by
random sampling ‘m’ of the predictors and choose the best split
among those variables.
3. Predict new data by aggregating the average predictions of the
‘t’ trees [16].
Figure 8: Working of Random Forest [17]
Cite The Article: Mr. Bhaskara P Achar, Mr. Grynal D’Mello, Dr. Srinivasa Pai P, Mr. Gururaj K. (2019). Use of vortex tube air cooling during machining of
Inconel 718: Experimental Investigation and Modeling studies. Journal of Mechanical Engineering Research and Developments, 42(5) : 127-131.
Figure 8 shows the working of Random Forest. The performance of
random forest is evaluated based on the prediction accuracy by
correlating between regression trees. From the available data set,
training sets are selected in random by considering the predictor
features at each node in order to choose the best split. The important
parameters required to be set in RFR include the number of trees, the
predictor variables for splitting the training and test data and the
specified nodes which limits the growing the regression trees [17].
In this study, RFR has been applied for the data generated during
machining of Inconel 718 using Statistica 12 [18]. Cutting speed, feed rate,
cutting temperature, cutting tool vibrations and flank wear have been
taken as input parameters to predict the surface roughness. A total of 44
data set have been generated during machining, out of which 80% have
been considered as training data and remaining 20% have been
considered as test data. The data has been normalized and used in RFR due
to lot of variation in the values of different parameters used as predictors.
All the values have been brought to the range between 0 and 1. The data
has been classified randomly into training and test by the software, based
on the percentage of distribution set by the user. Initially, the number of
trees has been set to 50 and the stopping criteria has been chosen as 10
cycles. The number of trees has been varied in order to get the best possible
prediction of surface roughness. Mean squared error (MSE) of observed
value and predicted value has been calculated using the following formula,
(1)
MSE was set with a cut off value of 0.05 and any value beyond that was
considered as misclassification. The data has been de-normalized before
calculating the prediction accuracy. It was found that at 100 number of trees,
RFR predicted the highest prediction accuracy of 94.28 % on training data
and 88.88 % on test data. The summary of RFR implemented in Statistica
is given in Fig. 9. It can be seen that the average squared error is decreasing
and remained almost stable at 100 number of trees. The results obtained
from RFR for test data is shown in Table 2.
Figure 9: Summary of RFR
Table 2: Results from RFR for test data
The significance of individual input parameters on surface roughness
during machining of Inconel 718 has been presented in the form of bar
graph of predictor importance shown in Fig. 11. It can be seen that cutting
temperature has been found to be a dominant parameter affecting surface
roughness followed by cutting tool vibrations and feed rate. Flank wear
and cutting speed showed least significance. The addition of three
uncontrollable parameters namely flank wear, cutting temperature and
cutting tool vibrations as independent variables, have not been
investigated earlier in the prediction of surface roughness during
machining Inconel 718 using Random Forest Regression and this study
tries to fill that research gap. Moreover, RFR has the ability to predict
surface roughness values better than Response Surface Methodology
(RSM) which is a widely used statistical technique for modeling and
prediction [19].
 Journal of Mechanical Engineering Research and Developments (JMERD) 42(5) (2019) 127-131
Figure 11: Importance plot of dependent variable Ra
5. CONCLUSIONS
Following conclusions were drawn after studying vortex tube cooling
assisted machining of Inconel 718
1. Flank wear and tool temperature during machining have been
found to be increasing with cutting speed and tool temperature as
high as 80°C was recorded which in turn affected the tool wear.
2. Surface roughness has been found to be better at low cutting speed
and low feed rate.
3. Vortex tube cooling has greatly reduced tool temperature during
machining irrespective of cutting speed and feed used.
4. At lower speed, vortex tube cooling has resulted in higher surface
roughness and flank wear and lower cutting tool vibrations.
5. Irrespective of use of air cooling or not, the cutting tool vibrations
reduce at the end of tool life for all the cutting speed and feeds
investigated.
6. Dry machining has been proved to be a better choice for obtaining
good surface roughness and longer tool life at lower cutting speeds.
7. Random Forest Regression technique predicted that the cutting
temperature is the dominant parameter influencing surface
roughness, followed by cutting tool vibrations and feed rate. Flank
wear and cutting speed were least significant variables. It gave a
prediction accuracy of 88.88 % on the test data.
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of Inconel 718: Experimental Investigation and Modeling studies. Journal of Mechanical Engineering Research and Developments, 42(5) : 127-131.
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