Effects of cutting fluid application in the performance of the Nimomic 80A turning

Renann Pereira Gama1, a * and Marcos Valério Ribeiro2,b

1,2
Univ. Estadual Paulista - UNESP - Faculty of Engineering, 333, Ariberto Pereira da Cunha Av. -
Guaratingueta-São Paulo - Zip Code 12516-410-–Brazil
a b
renann.gama@hotmail.com, marcos.valerio@pq.cnpq.br

Keywords: Machining, Superalloy, Nimonic 80A, Flank wear, Roughness.

Abstract. The increase of world requirements for improved products allied to growing competition between companies in
the global market makes the same seek processes that ensure lower costs allied to high productivity and high quality
product. Thus the great industrial and technological development has increased the search for machining processes that
promote, for example, high performance as regards the chip removal, less tool wear and failure and reduced impact on the
environment. Regarding nickel-based superalloys, they have an extremely important role in the aeronautical and
automotive industries among others. The nickel-based superalloy studied is the Nimonic 80A, difficult to machine material
that has high mechanical strength and corrosion resistance at higher temperatures. The objective of this work is to study the
influence of the application of cutting fluids in turning and the machining parameters in order to achieve high performance
and optimization of machining this alloy. The alloy was machined using various machining parameters: cutting speed, feed
rate, cutting depth, Minimum Quantity fluid (MQF), and Fluid abundant. After turning chip samples were obtained, was
measured the surface roughness, volume of chip removed, cutting length and macro structural analyzes were performed
and of lifetime of the tools used in order to detect possible wear, as well as, microstructural analyzes of the chips by optical
microscopy, scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS).In this work can observe the
behavior of the materials and tools in the two cooling conditions used, as well as, the impacts of the parameter variations in
the surface finish, on the structure of the material and performance of the tools in respect chip removal regarding volume
removed and machined length. Application by MQF was promising, but there is abundant beyond the traditional
application.

Introduction
The development of metallic materials is intimately associated to technological advances. The necessity of materials to
be more resistant to wear, corrosion/oxidation and tougher, has been the impulse for the research of many materials.
Originally, the stainless steels and alloyed steels were used, but the necessity of an operation at higher temperatures,
encouraged the development of the refractory alloys or “superalloys”.
The use of the nickel based alloys in the aeronautical and rocket engineering field is mainly because of their great
performance at high temperatures, which is given for some of its intrinsic characteristics, such as having a high mechanical
strength at elevated temperatures, a high creep resistance, a high resistance to fatigue, and corrosion resistance [1] and [2].
The nickel alloys have a chemical composition containing high levels of alloying elements, which are responsible for
their mechanical and thermal properties, but these characteristics make its machining excessively difficult, causing some
problems during the process [2].
The main difficulties in machining these alloys can be summarized as: high strength and hardness at high temperatures;
the austenitic matrix of the nickel alloy promotes a fast hardening; the presence of hard carbides and abrasives in the
microstructure; the low thermal conductivity, and the weldability of the workpiece material in the cutting edge of the tool
[3].
It is important to emphasize that the change in the surface, as the residual stress during the machining, can result in
unfavorable distortions to the workpiece. For this reason, special care must be taken to ensure the lifetime of the tool, the
workpiece surface integrity, and the control of the main machining parameters [2]. Therefore, to obtain satisfactory
machining conditions, it is necessary to have a good understanding of the microstructure of the involved materials, the
effects about the behavior of the cutting tools, and on the efficiency of the utilized machining processes [4].
The use of conventional refrigeration (abundant) is not way to the improvement of conditions of the machining of
superalloys because the refrigerant is unable to reach the cutting zone due to the formation of steam that prevents the
penetration of refrigerant into the high temperature zone. The flow of chip can to impede access by refrigeration in the
cutting zone. The administration of refrigeration directly in the cutting zone is required to ensure an efficient and economic
machining of the superalloys. High pressure of refrigerant, cryogenic refrigeration and Minimum Quantity Fluid - MQF are
techniques used for achieve this goal [3].
The use of MQF is a technology developed which consists of administering small quantities of lubricant in the tool-chip
interface during the machining. In this technique are used about 6 to 70 ml/h of refrigerant/lubricant against 300 to 4000
ml/min. used in abundant lubrication [5]. The technique of MQF involves the application of a small quantity of water and
soluble oil, used through of compressed air which propels the solution by means of a jet sprayed in the cutting edge from
tool. This technique has demonstrated successful in grinding processes, milling and turning [6].
 With this work was sought to understand the behavior of materials and tools in the two lubrication conditions used,
besides understanding the effects of parameter variations in the surface finish, in the structure of the material and
performance of the tools in relation to the volume of material removed and machined length.

Experimental Procedures
Materials
The Nimonic 80A superalloy, used was produced by the hot-rolled process with average hardness of HRC 50.5. In the
Table 1 is shown the composition of the alloy used in the tests. The workpieces dimensions were: Length = 180 mm and
Diameter = 50 mm.

Table 1 – Composition of the superalloy [%].

Alloy Ni Cr Co Al Ti Mn Si C
Nimonic 80A 74,7 19,5 1,1 1,3 2,5 0,1 0,7 0,06

The tools used in the tests as indicated by the manufacturer (Sandvik) for superalloys machining, were coated hard
metal pads TNMG 160408-23 Class S15 (GC 1105). This tool (Sandvik GC 1005) was chosen because they present good
resistance against plastic deformation and excellent hardness at elevated temperatures(Sandvik, 2005). The tests were
performed on a CNC MACH-9-Centur 30S, 25 to 3500 rpm, with power of 7.5 CV, ROMI.
The cutting fluid used for abundant lubrication was the Lubrax OP-38-EM that consists in an oil emulsion of
naphthenic base. The cutting fluid flow during the tests was at approximately 4.8 liters/minute. For the tests developed with
the Minimum Quantity of Fluid (MQF) technique the Accu-lube equipment was used, which is manufactured by ITW
Chemical Products Ltd. The vegetable-based lubricant LB 1000 was used according to the manufacturer's instructions. The
flow and pressure for the test were adjusted to 5 ml/h and 5 bar, respectively. The equipment was placed about 30 mm of
the tool and directed to the rake face.

Methodology
The process used in the tests was the cylindrical external turning that were conducted so that, at each pass realized in in
the workpiece, it was removed from the lathe, its diameter and tool wear were measured, and chip samples were collected
for analysis. The criterion chosen for the ending lifetime of the tool was the maximum flank wear (VBc), which equals 0.5
mm. The parameters used for the machining are showed in the Table 2.

Table 2 - Parameters used for the machining.

f [mm/rot] Vc [m/min] ap [mm]
Lubrication
Feed rate Cutting speed Cutting depth
0,15
75
Abundant 0,18
0,15 0,8
90
0,18
0,15 75
MQF
0,15 90
When the lifetime of the tools was reached (VBc = 0.5 mm), they were identified and subsequently forwarded to the
Zeiss stereoscope to measure the wear.

Preparation of the Material

In this study the samples were embedded with hard epoxy resin of high resistance so that they could be prepared by
sanding and polishing with subsequent etching, so that finally were obtained its micrographs. The proportion of reagent is
defined in Eq. (1):

HCl + HNO3 + H2SO4 (90 ml: 3 ml: 5 ml respectively) (1)

The best results were obtained with 35 seconds of etching at 26 °C. For the revelation of the microstructure, immersion
was the etching method used. The samples were analyzed by the Scanning Electron Microscope - SEM and for the
constituents to be identified and quantified using the EDS (Energy Dispersive Spectroscopy).
Results and Discussion
Abundant Fluid
In the Fig. 1 is presented the evolution of the tool life to the parameters 75-15-8 and 75-18-8 with abundant lubrication,
can be noted that there is an increase in the tool life for higher feed rates. This effect can be due the probable elevation of
the temperature of the workpiece that cause a reduction of the hardness that facilitates the cut.
Very high feed rates the effect of hardness reduction is surpassed by high temperatures in the cutting edge that causes a
loss of hardness of the tool due to the low thermal conductivity of the nickel superalloys, accelerating the degradation of
the coating and the tool wear [7].

Figure 1 - Tool life “comparative between cutting speed”

The evolution of tool life for the parameters 90-15-8 and 90-18-8 with abundant lubrication is presented too in the Fig.
1, is possible to perceive that just like in the graph 1occurs the same elevation of the tool life with the increase of the feed
rate.
It is showed too in the fig. 1 a comparison between the tool life to both cutting speeds used 75 m/min and 90 m/min. As
mentioned previously can be noticed an elevation of the tool life following the increase of the feed rate, also is possible
compare the tool life when used each cutting speed utilized. So comparatively can be seen that for lower cutting speeds the
tool reached superior life, between 19,13 and 20,86 min for cutting speed of 75 m/min, against 3,99 and 8,70 min for
cutting speed of 90 m/min. This effect can be associated at higher temperatures in the cutting edge when used higher
cutting speeds. However can be observed that there was largest percentage increase of the tool life in the cutting speed of
90 m/min with the increase of the feed rate, been this increase of 118,04% against 9,04% for the cutting speed of 75 m/min.
Analyzing the tool life in relation at chip generated is possible infer that the tool life was superior for longer chips, been
this generally formed in the cutting speed of 75 m/min in the beginning of the process. It is possible perceive too more chip
regularity with the parameters 75-15-8. Probably this regularity is associated at lower temperatures reached during the tests
with these parameters, sufficient to reduce the workpiece hardness without compromise the tool seriously.
In the tools of the Fig. 2 can be noted that the flank wear was bigger in the image (b) in that the parameters used
were90-15-8, also is important observe a possible material adhesion forming a built up edge cutting that creates changes in
the geometry of the tool reducing the material remove capacity and the tool life considerably. In the image (a) the
parameters used were 75-15-8 where it its evident the presence of notch in the tool edge and the flank wear in lower
intensity that in the previous parameters. Thus for higher cutting speeds the flank wear is more visible and with presence of
others types of wear that occur due the higher activation energy generated by the process, not to mention that invariably
have more of a type of wear associated at process.

(a) (b)
Figure 2 – Tool wear (a) parameters 75-15-8 and (b) parameters 90-15-8

In the Fig. 3 is presented the volume of chip removed for the parameters 75-15-8 and 75-15-8. In the analyze this
graphic is possible note that for the feed rate of 0,18 mm/rot was reached a higher chip volume value (225,31 cm3) when
compared at feed rate of 0,15 mm/rot that reached 172,18 cm3. There is a tendency in the increase of the volume of chip
removed with the increase of the feed rate until the apex with feed rate of 0,18 mm/rot. It is possible infer still that this
increase in the chip volume due the increase of the feed rate was of approximately 30,8% of feed rate for the other [7].
 With respect at chip volume for the cutting speed 90 m/min can be seen too in the fig. 3 the same effect of increase of
the chip volume with the increase of the feed rate. This increase in order of 161,3%.
With the Fig. 3 is possible to do a comparison between the cutting speeds and the feed rates used. Thus with respect at
feed rate of 0,15 mm/rot, it is possible to note that for lower cutting speeds the volume of removed chip increase, possibly
due to the tool life be increased in lower cutting speeds. Thus occurred an increase of 299,2% of volume of removed chip
for the cutting speed of 75 m/min in comparison with the 90 m/min with the feed rate of 0,15 mm/rot. For the feed rate of
0,18 mm/rot the difference between both cutting speeds was 99,92% higher for the cutting speed of 75 m/min.

Figure 3 – Volume of removed chip Figure 4 - Average roughness (Ra)

“comparative between cutting speeds”
In the Fig. 4 can be seen that the feed rate of 0,15 mm/rot was obtained the better finish in both cutting speeds. The
elevated roughness value for the parameters 75-15-8 can be explained due to the high deterioration rate of the cutting edge
and the existence of material adhered in the tool modifying thus the geometry and influencing in the tool tip radius as can
be seen in the Fig. 5.

Figure 5 – Tool used with the parameters 75-15-8

From Fig. 6 is still more evident the presence of workpiece material in the tool, inclusive the presence of chip adhered.
Analyzing the frayed surface in the Fig. 6 is possible by EDS identify the elements in the tool edge in different colors.

Figure 6 – MEV of the tool used with the Figure 7 – MEV of the tool used with the
parameters 75-18-8 parameters 75-18-8 using EDS
 From Fig. 7 is possible see the presence of the nickel in red color being this element the principal constituent of the
alloy, thus is evident that all nickel found is wokpiece material adhered in the tool because the nickel is not found in the tool
composition. Still of easy identification, it is possible to see in green color the presence of large part of tool coating
(TiAlN) evidenced by presence of Aluminum and Titanium. In blue color is possible to see the Tungsten element found in
the tool substratum.
In the Fig. 8 can be related the roughness with the cutting length and the parameters utilized, thus é visible that in terms
of surface finish and efficiency of cutting length the better will be choose the parameters 75-15-8 that have the lower
roughness value and second higher cutting length.

Figure 8 – Roughness x Cutting length

MQF
For the application of MQF was used only the parameters 75-15-8 and 90-15-8, this because with the change of the
cutting speeds there is not an increase of the contact area between tool and workpiece which could minimize the
temperature gradients such as happens with the increase of the feed rate. Thus is possible analyze the effects of the cutting
speeds in the machining of the alloy with the use of MQF.
In Fig. 9 is presented the tool life for both cutting speeds. It is possible to see by the Fig. 9 that tool life decrease with
the increase of the cutting speed that generate higher temperature gradients favoring the wear mechanisms. In the Fig. 10 is
showed that the volume of the chip removed is higher for low cutting speeds than for high cutting speed.

Figure 9 – Tool life x Cutting speed Figure 10 – Evolution of Volume of chip

removed
The values of roughness are presented in the fig. 11 and is possible infer that in lower cutting speeds the roughness was
better than in higher cutting speeds.

Figure 11 – Roughness (Ra) for MQF

As with the abundant lubrication in the MQF was observed the presence the material adhered on the tool edge forming
built up edge cutting and a large part of the substratum exposed as fig. 12, 13 and 14.
 Figure 12 – Tool used with parameters 75-15-8 using MQF

Figure 13 – MEV of the tool used with Figure 14 - MEV of the tool used with parameters 75-15-8 using
parameters 75-15-8 using MQF MQF and EDS Microstructural Analysis
In the Fig. 15 is shown the grain boundaries and two deformation zones called of primary deformation zone and
secondary deformation zone. The primary deformation zone (blue arrow) is the region of the chip that occurred a shearing
followed of a localized weld. The secondary deformation zone (red arrow) is the region where the chip slid over the rake
surface. In all parameters and in the two lubrication conditions was observed the same comportment, primary and
secondary zones defined with evidenced grain boundaries and equiaxial grains (green arrow).

50 µm

Figure 15 – Chip generated with parameters 75-15-8 and abundant lubrication

Conclusion
This study possibilities a comparison between machining parameters in two lubrication conditions (abundant and
MQF). In relation at application of abundant lubrication can be seen that the parameters used promoted a higher tool life
with great volume of removed chip and good finish in comparison to the MQF application.
In relation at MQF application was observed insufficient values of roughness, volume of the chip removed and tool life
not justifying his utilization although ecologically correct.
 All parameters used and in both lubrication conditions presented material adhered in the tool generated modification in
the cutting edge, thus difficulty the machining. It was observed that the tool presented higher flank wear values confirming
the difficulty of machining this alloy. The process presents better results when used lower cutting speeds and higher feed
rates.

Acknowledgements
The authors wish to thank CAPES, FAPESP, SANDVIK and VILLARES METALS for support.

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