Determination of MQL Parameters Contributing to Sustainable Machining in the Milling of Nickel-Base Superalloy Waspaloy

In addition to reducing production costs, minimum quantity lubrication (MQL) aims to minimize the adverse effects of conventional cutting fluid usage on the environment and human health. Because of the positive effect of the MQL system on both health and production efficiency, sustainable production is increasing daily. Therefore, optimum MQL parameters must be determined in order to obtain maximum efficiency in the manufacturing process. In this study, unlike similar studies in which MQL parameters were evaluated, the scope was widened and the main parameters affecting the efficiency of the system were tested at the same time. For this aim, nickel-base superalloy Waspaloy was machined under MQL using a CNC milling machine with uncoated carbide inserts. In the machining process, the MQL parameters selected were cutting oil type (mineral-, synthetic-, mineral-synthetic- and vegetable-based oils), fluid flow rate (25, 50, 75 and 100 ml/h), milling method (up milling and down milling), spray distance (25 and 50 mm) and nozzle type (Type 1 and Type 2). In order to analyze the effect of MQL parameters on the quality characteristics of tool life and cutting force, the cutting parameters, including cutting speed, feed rate and depth of cut, were kept constant for all experiments. Taguchi’s L16 $$(4^{2}\times 2^{3})$$(42×23) orthogonal array was employed to minimize the number of experiments. As a result, both maximum tool life and minimum cutting force were attained via a combination of vegetable-based cutting oil, 100 ml/h flow rate, opposite-direction (up) milling, Type 1 nozzle and a 25-mm spray distance.

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