Top

International Journal on Interactive Design and Manufacturing (IJIDeM)

10-02-2025 | Original Article

Advanced machining of inconel 690 using alumina-enriched sunflower oil-based lubricant: a genetic algorithm-driven approach

Authors: Abhijit Bhowmik, Raman Kumar, Ramdevsinh Jhala, N. Beemkumar, Ambati Vijay Kumar, Ankit Kedia, K. Durga Hemanth Kumar, Gurpartap Singh

Published in: International Journal on Interactive Design and Manufacturing (IJIDeM)

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

This study explores the potential of using vegetable oil enhanced with nanoparticles as a metalworking fluid. Various alumina concentrations (0–1%) were mixed into sunflower oil, and thermo-physical properties analysis was used to identify the optimal concentration of alumina nanoparticles. Subsequently, hard milling of Inconel 690 was performed in diverse lubrication conditions: dry, compressed air, sunflower oil, and sunflower oil with alumina. The comparative analysis revealed that sunflower oil with 0.8% alumina significantly outperformed the other conditions, reducing surface roughness, cutting force, and cutting temperature by 42.28%, 27.40%, and 23.44%, respectively, compared to dry cutting. Finally, twenty-seven Taguchi-based experiments were conducted under the best lubrication conditions, and a Genetic Algorithm (GA) was employed to optimize the machining environment. Practical experiments confirmed the optimized conditions, showing that the mean error between experimental and predicted results was 0.37%. The novel combination of eco-friendly lubrication and AI-driven optimization addresses critical challenges in machining efficiency and sustainability, offering a framework for reducing energy consumption, minimizing environmental impact, and improving tool longevity. The findings highlight a transformative approach to sustainable manufacturing, advancing the application of nano-green lubricants in machining superalloys.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Wirtschaft"

Online-Abonnement

Mit Springer Professional "Wirtschaft" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 340 Zeitschriften

aus folgenden Fachgebieten:

Bauwesen + Immobilien
Business IT + Informatik
Finance + Banking
Management + Führung
Marketing + Vertrieb
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Darshan, C., Jain, S., Dogra, M., Gupta, M.K., Mia, M., Haque, R.: Influence of dry and solid lubricant-assisted MQL cooling conditions on the machinability of Inconel 718 alloy with textured tool. Int. J. Adv. Manuf. Technol. 105, 5–6 (2019)

Inasaki, I.: Towards symbiotic machining processes. Int. J. Precis Eng. Manuf. 13(7), 1053–1057 (2012)CrossRefMATH

Gupta, M.K., et al.: Experimental characterisation of the performance of hybrid cryo-lubrication assisted turning of Ti–6Al–4V alloy. Tribol Int. 153, 106582 (Jan. 2021). https://doi.org/10.1016/j.triboint.2020.106582

Singh, R., Dureja, J.S., Dogra, M., Kumar Gupta, M., Jamil, M., Mia, M.: Evaluating the sustainability pillars of energy and environment considering carbon emissions under machining ofTi-3Al-2.5 V. Sustain. Energy Technol. Assessments. 42, 100806 (2020)CrossRef

Yang, X., Cheng, X., Li, Y., Zheng, G., Xu, R.: Machinability investigation and sustainability analysis of minimum quantity lubrication–assisted micro-milling process, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 234, no. 11, pp. 1388–1401, Sep. (2020)

Fox, N.J., Stachowiak, G.W.: Vegetable oil-based lubricants—a review of oxidation. Tribol Int. 40(7), 1035–1046 (2007)CrossRefMATH

Xiao, Z., Shi, C., Mao, D.: Effect of tocopherol on antioxygenic properties of green lubricating oil. J. Wuhan Univ. Technol. Sci. Ed. 23(3), 289–292 (2008)CrossRefMATH

Sayuti, M., Erh, O.M., Sarhan, A.A.D., Hamdi, M.: Investigation on the morphology of the machined surface in end milling of aerospace AL6061-T6 for novel uses of SiO2 nanolubrication system, J. Clean. Prod., 66, pp. 655–663, Mar. (2014)

Sen, B., Mia, M., Mandal, U.K., Mondal, S.P.: Synergistic effect of silica and pure palm oil on the machining performances of Inconel 690: A study for promoting minimum quantity nano doped-green lubricants, J. Clean. Prod., 258, p. 120755, Jun. (2020)

10.

Sen, B., Gupta, M.K., Mia, M., Mandal, U.K., Mondal, S.P.: Wear behaviour of TiAlN coated solid carbide end-mill under alumina enriched minimum quantity palm oil-based lubricating condition. Tribol Int. 148, 106310 (Aug. 2020)

11.

Sivalingam, V., et al.: Aug., Wear behaviour of whisker-reinforced ceramic tools in the turning of Inconel 718 assisted by an atomized spray of solid lubricants, Tribol. Int., 148, p. 106235, (2020)

12.

Zhang, Y., Li, C., Jia, D., Zhang, D., Zhang, X.: Experimental evaluation of MoS₂ nanoparticles in jet MQL grinding with different types of vegetable oil as base oil, J. Clean. Prod., 87, no. C, pp. 930–940, Jan. (2015)

13.

Jia, D., et al.: Specific energy and surface roughness of minimum quantity lubrication grinding Ni-based alloy with mixed vegetable oil-based nanofluids. Precis Eng. 50, 248–262 (2017)CrossRefMATH

14.

Singh, H., Sharma, V.S., Dogra, M.: Exploration of graphene assisted vegetables oil based minimum quantity lubrication for surface grinding of TI-6AL-4V-ELI. Tribol Int. 144, 106113 (2020)CrossRef

15.

Gajrani, K.K., Suvin, P.S., Kailas, S.V., Mamilla, R.S.: Thermal, rheological, wettability and hard machining performance of MoS₂ and CaF₂ based minimum quantity hybrid nano-green cutting fluids, J. Mater. Process. Technol., 266, pp. 125–139, Apr. (2019)

16.

Singh, H., Sharma, V.S., Singh, S., Dogra, M.: Nanofluids assisted environmental friendly lubricating strategies for the surface grinding of titanium alloy: Ti6Al4V-ELI, J. Manuf. Process., 39, no. February, pp. 241–249, (2019)

17.

Pal, A., Chatha, S.S., Sidhu, H.S.: Experimental investigation on the performance of MQL drilling of AISI 321 stainless steel using nano-graphene enhanced vegetable-oil-based cutting fluid. Tribol Int. 151, 106508 (2020)CrossRefMATH

18.

Şenol, Ş., Sarıkaya, M., Yıldırım, Ç.V., Kıvak, T.: Machinability performance of nickel alloy X-750 with SiAlON ceramic cutting tool under dry, MQL and hBN mixed nanofluid-MQL. Tribol Int. 153, 106673 (2021)CrossRef

19.

Öndin, O., Kıvak, T., Sarıkaya, M., Yıldırım, Ç.V.: Investigation of the influence of MWCNTs mixed nanofluid on the machinability characteristics of PH 13 – 8 Mo stainless steel. Tribol Int. 148, 106323 (2020)CrossRef

20.

Ali Khan, M., et al.: Dec., Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions, Mech. Sci., 10, no. 2, pp. 561–573, (2019)

21.

Shi, K., Zhang, D., Ren, J.: Optimization of process parameters for surface roughness and microhardness in dry milling of magnesium alloy using Taguchi with grey relational analysis, Int. J. Adv. Manuf. Technol., 81, no. 1–4, pp. 645–651, Oct. (2015)

22.

Coppel, R., Abellan-Nebot, J.V., Siller, H.R., Rodriguez, C.A., Guedea, F.: Adaptive control optimization in micro-milling of hardened steels—evaluation of optimization approaches. Int. J. Adv. Manuf. Technol. 84, 9–12 (Jun. 2016)

23.

Malghan, R.L., Rao, K.M.C., Shettigar, A.K., Rao, S.S., D’Souza, R.J.: Application of particle swarm optimization and response surface methodology for machining parameters optimization of aluminium matrix composites in milling operation. J. Brazilian Soc. Mech. Sci. Eng. 39(9), 3541–3553 (Sep. 2017)

24.

Cica, D., Kramar, D.: Multi-objective optimization of high-pressure jet-assisted turning of Inconel 718, Int. J. Adv. Manuf. Technol., 105, no. 11, pp. 4731–4745, Dec. (2019)

25.

Sen, B., Mia, M., Mandal, U.K., Dutta, B., Mondal, S.P.: Multi-objective optimization for MQL-assisted end milling operation: an intelligent hybrid strategy combining GEP and NTOPSIS, Neural Comput. Appl., 31, no. 12, pp. 8693–8717, Dec. (2019)

26.

Sen, B., Mia, M., Krolczyk, G.M., Mandal, U.K., Mondal, S.P.: Eco-Friendly Cutting Fluids in Minimum Quantity Lubrication Assisted Machining: A Review on the Perception of Sustainable Manufacturing, International Journal of Precision Engineering and Manufacturing - Green Technology, 8, no. 1. Korean Society for Precision Engineeing, pp. 249–280, Jan. 01, 2021

27.

Paul, S., Ghosh, A.: Suitability of aqueous MoS ₂ nanofluid for small quantity cooling lubrication–assisted diamond grinding of WC-Co cermets, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 233, no. 2, pp. 426–442, Jan. (2019)

28.

Mia, M., Dhar, N.R.: Prediction and optimization by using SVR, RSM and GA in hard turning of tempered AISI 1060 steel under effective cooling condition. Neural Comput. Appl. 31(7), 2349–2370 (2019)CrossRefMATH

29.

Qu, S., Zhao, J., Wang, T.: Experimental study and machining parameter optimization in milling thin-walled plates based on NSGA-II. Int. J. Adv. Manuf. Technol. 89, 5–8 (2017)CrossRefMATH

30.

Sen, B., Hussain, S.A.I., Mia, M., Mandal, U.K., Mondal, S.P.: Selection of an ideal MQL-assisted milling condition: An NSGA-II-coupled TOPSIS approach for improving machinability of Inconel 690. Int. J. Adv. Manuf. Technol. 103, 5–8 (Aug. 2019)

31.

Sen, B., Mia, M., Mandal, U.K., Mondal, S.P.: GEP- and ANN-based tool wear monitoring: a virtually sensing predictive platform for MQL-assisted milling of Inconel 690, Int. J. Adv. Manuf. Technol., 105, no. 1–4, pp. 395–410, Nov. (2019)

32.

Sen, B., Kumar, R., Kanabar, B., Kedia, A., Kumar, A.V., Bhowmik, A.: Comparative Analysis of NSGA-II and TLBO for Optimizing Machining parameters of Inconel 690: A sustainable Manufacturing paradigm. J. Mater. Eng. Perform., 1–16. (2024). https://doi.org/10.1007/s11665-024-10468-9

33.

Palanisamy, P., Rajendran, I., Shanmugasundaram, S.: Optimization of machining parameters using genetic algorithm and experimental validation for end-milling operations. Int. J. Adv. Manuf. Technol. 32, 644–655 (2007)CrossRefMATH

Title: Advanced machining of inconel 690 using alumina-enriched sunflower oil-based lubricant: a genetic algorithm-driven approach
Authors: Abhijit Bhowmik
Raman Kumar
Ramdevsinh Jhala
N. Beemkumar
Ambati Vijay Kumar
Ankit Kedia
K. Durga Hemanth Kumar
Gurpartap Singh
Publication date: 10-02-2025
Publisher: Springer Paris
Published in: International Journal on Interactive Design and Manufacturing (IJIDeM)
Print ISSN: 1955-2513
Electronic ISSN: 1955-2505
DOI: https://doi.org/10.1007/s12008-025-02246-1

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Springer Professional "Wirtschaft"