Investigations in sustainable grinding of Inconel 718 superalloy using alumina

grinding wheel
Manoj Kumar Sinha*
*Asst. Professor, National Institute of Technology Delhi – 110 040
*Research Scholar, Indian Institute of Technology Delhi – 110 016
Email: [email protected]
Abstract: This work explores the grindability improvement of Inconel 718 (IN-718) under dry, flood cooling
technique (FCT), minimum quantity cooling and lubrication (MQCL) and liquid nitrogen environments. The
coolant flow rate in MQCL and liquid nitrogen grinding has been regulated through in-house designed and
developed arrangements. Grinding forces have been measured on-line in surface grinding experiments.
Measured tangential forces have been used in the calculation of specific grinding energy. Additionally, scanning
electron microscopy (SEM) study and Energy dispersive X-ray spectroscopy (EDX) analysis of grinding chips have
been performed. From the present experimental findings, it is observed that liquid nitrogen grinding has proven
its effectiveness in the form of lower grinding forces, least specific energy, and least oxidation of ground
surfaces. Small C type chips formed in grinding under MQCL and liquid nitrogen cryogenic conditions indicates
the effective cooling under these environments. The findings of the EDX analysis of the grinding chips also
support the finding of the present study through highest oxidation in dry grinding compared to MQCL and
cryogenic grinding. From this work, it has been concluded that cryogenic grinding and MQCL grinding offer a
clean and a cost-effective means to improve the grinding process performance compared to dry and FCT
grinding.
Keywords: Inconel 718, grinding, grinding force, FCT, MQCL, cryogenic grinding.
1. Introduction
Grinding is a high specific energy-intensive secondary manufacturing process. The high energy requirement
in grinding can be attributed to the inherent multi-point cutting mechanisms, physical as well as geometrical
parameters and distribution of abrasive grits. This high specific energy consumption in this process culminates
in the high heat generation and eventually results in a high-temperature rise in the grinding zone [1]. Such high
heat may cause thermal damages like surface oxidation (burn), surface crack development, tensile residual
stress, microstructural alteration to the work surface and quick wheel wear. Therefore, to safeguard the ground
surface from such thermal damages and minimise the wheel wear, the heat generated needs to be controlled
and removed quickly as the contact period between the contacting surfaces is in the order of microseconds.
Quick heat removal can be accomplished through the application of suitable and appropriate cutting fluid. The
simplest and most common cutting fluid delivery system is FCT, in which considerable large quantity of
pressurised cutting fluid is introduced into the grinding zone. Manufacturing industries have adopted this
technique for many years. With the passage of time, concerned people and researchers realised that FCT has
many inherent limitations. In this technique, hardly a fraction of cutting fluid injected is utilised in cooling and
lubrication, and hence, a substantial portion of the cutting fluid injected remains unutilised. The large volume of
the cutting fluid has indeed resulted in large storage, more disposal, and more pumping power requirement.
Many researchers had pointed the fact that the cooling cost almost accounts for 15 to 20 % of the total
manufacturing cost of the component which is a significant chunk of the total manufacturing cost [2-5].
Moreover, FCT technique has been reported as one of the biggest contributors to the environmental pollution.
Hence, nowadays due to the spread of public awareness about its limitations, strict environmental regulations
and adaptation towards environment-friendly green manufacturing techniques, the research trend is getting
inclined towards the minimal usage of the cutting fluids. Such alternative techniques are known as environment-
friendly sustainable techniques. It includes the minimum quantity cooling and lubrication (MQCL), cryogenic
cooling, high-pressure cooling, vapour cooling, and hybrid cooling.
In manufacturing practices, MQCL has various synonyms such as minimum quantity lubrication (MQL), small
quantity lubrication (SQL), near dry machining and micro-litre lubrication. In this method, a small quantity of the
cutting fluid mixed with pressurised air is injected into the grinding zone. From economic and ecological
considerations, MQCL finds an irreplaceable position in machining domain. The application of cryogenic cooling
in grinding is another important environment-friendly cutting condition. Normally, the term cryogenics deals
with the science of very low temperature. In cryogenic machining, a suitable cooling medium known as cryogen
is used as the cooling medium during the machining operation. However, in machining cryogenic captured a
significant dominance, especially in, steel, Ti and Ni alloys machining predominantly due to its abundance and
inert behaviour. Liquid nitrogen is produced industrially by the fractional distillation of liquid air. It is the most

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abundant colourless, odourless, tasteless and non-toxic gas. More importantly, the nitrogen discharged into the
atmosphere during machining processes is safe about the operator’s health, workplace and the environment.
Therefore, there seems to be a collective responsibility of the research community to direct the machining arena
towards adaptation of these sustainable techniques in their work. Table 1 presents few significant differences
between the conventional FCT, MQCL and cryogenic technique based on a few key parameters:

Table 1 Comparison between FCT, MQCL, and cryogenic conditions [1, 4, 6-8].
Sr. No. Parameters FCT MQCL Cryogenic
1 Volume of cutting Thousands of litres per Few millilitres per Few litres of cryogen
fluid hour hour per hour
(50 to 500 ml/h)
2 Cost of cutting Around 20% of total Small percentage of Substantial
fluid production cost total production cost percentage of total
production cost
3 Effectiveness of Only a small percentage Almost total volume of Substantial portion of
cutting fluid of cutting fluid cutting fluid total volume
4 Accessories A large number of Few mandatory Few mandatory
requirement accessories like big accessories accessories
storage tank, pump, etc.
5 Disposal and Difficult and costly No need for disposal No need for disposal
recycling and recycling and recycling
6 Hazards Pollute workspace & No such effect to the No such effect to the
environment that can operator and operator and
cause skin-borne disease workspace workspace
to operator
7 Present scenario Limited usage Widely used In growing stage
Nowadays, a lot more improvement and innovations took place in the development and application of high
strength alloys and superalloys. Ni-based superalloys are one of such superalloys getting wide appreciation and
being used worldwide due to their superior mechanical properties. IN-718, an austenitic structure alloy is one
of the most commonly used Ni-based superalloy primarily for its capability to withstand high temperature and
severe operating conditions. IN-718 appears as one of the leading superalloys in industrial applications,
accounting for almost 70% of Ni-based alloy production [9]. It has high strength, high ductility, and fatigue
resistance. Moreover, it exhibits high corrosion, fracture and creep resistance which appears to be the specific
properties of the austenitic alloys. Therefore, it is widely used in chemical, nuclear, military, marine, submarine,
aerospace and power industries in making important components. For such severe operating conditions, surface
quality becomes more crucial, which can be generated using grinding process. IN-718 has high hardness, severe
strain hardening, low plasticity, and smaller thermal conductivity, which makes this material difficult to grind
(DTG) and has the machinability rating of 15 out of 100 scale[10].
Detailed, concise and summarised literature of applicability of MQCL and cryogenic in grinding has been
investigated and is presented in Table 2. The tabular form of the comprehensive literature summary may be
quite useful in providing the first-hand information to the associated researchers in the domain of environment-
friendly grinding. This summarises the potential application of these green environments in grinding of
important engineering materials. From the cited literature, it is evident that in the present scenario, these
techniques are one of the prime accepted and appreciated cutting environments in the manufacturing sector.
From the literature tabled, it is apparent that till now MQCL and cryogenic grinding have been used in grindability
improvement in various steel alloys, Ti alloys, and few Ni alloys as well. However, till now virtually no work has
been reported for MQCL and cryogenic grinding of IN-718. Therefore, the present work is an attempt to
experimentally investigate the grinding performance improvement of IN-718 under MQCL and liquid nitrogen
(cryogenic) environments. Further, the grinding responses of these conditions have been compared with those
obtained in the case of dry grinding and FCT grinding of IN-718.

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 Table 2 Summary of available literature on MQCL and cryogenic application in grinding.

Grinding parameters MQCL parameters

Responses
Reference Grinding environment Work material Flow rate Air pressure Stand-off
Vc (m/s) Vw (m/min) d (µm) studied
(ml/h) (bar) distance (mm)
[1] Water miscible with mineral oil S34700 and AA6061 30 1.5 5,15,25 100 4 - SR,F,SM
[11] Dry, wet, MQL Hardened 100Cr6 30 1 20 20,50,100 2,3,4,7 40,60,80,120 SR,F,
[4] Semi-synthetic based vegetable oil Ceramic – Alumina rings 30 35 2.5,3.7 120 6.8 - P,SR,RE
[12] MoS2, CNT synthetic lipids as base fluid GH4169 Ni-based alloy 30 3 10 50 6 12 F,SR
CK45,S305,HSS,100Cr6
[13] Dry, FCT,MQL 30 3 5,20,35,50 120 4 - F,SR
steel
[14] FCT,MQCL - vegetable oil AISI 4340 steel 33 20 - - 6.5 35 SR,M,H
[15] FCT,MQCL - vegetable oil AISI 4340 steel 30 5 100 6 - P,SR,H,W
[16] Vegetable and synthetic oil AISI 4140 steel 30 10 to 40 5,10,15 15 to 140 2,3,4,5,6 50 F,SR,H,SM,M
[17] Synthetic oil, MoS2, CNT, ZrO2 Hardened steel 45 35 3 20 30 5 - F,SR,SM,SE
[18] Dry, cold air, MQCL - Soluble oil Plain carbon steel 1045 23 0.4 5,10,15,20 9.6 3 80 F,SR,H,RS
[19] Dry, FCT,MQL oil ABNT 4340 steel 30 20 100 40 - 35 SR,H,RS,M
[20] Dry, FCT, MQL - Castrol oil 100Cr6 and 42CrMo4 steel 20,25,30 2.5,5,10 5,10,15,25 66 4 - F,SR, SM,CM
[21] Vegetable oil & synthetic oil Ti–6Al–4V alloy 15 20,30,40 2,5,7 20 - 140 3, 4, 5, 6 45 F,SR,H,SM,M
[22] Dry, FCT, MQCL-synthetic oil EN8, M2,EN31 steel 25, 45 6.5,15 5,15 33 4 - P,F,T,SR
[23] Dry, fluid, air jet, MQCL-5% Castrol oil 100Cr6 hardened steel 30 3 30 100 4 80 F,SR,SM,CM
[24] Dry, FCT, MQCL-synthetic oil EN8, M2,EN31 steel 25,45 15 5,15 33 4 - P,F,SR, T
[25] Synthetic oil SK3 steel - - 50 1.88 5 30 SR, MRR
[26] Pure oil, oil & water AISI 52100 steel 31.4 3 10 60 6 - F,SR,T,SM,M
[27] Paraffin oil with MoS2 100-70-03 Cast iron 30 3.6, 6 20 150 4.13 - SE, µ,M,G,T
[28] MQL - Cimtech D14 oil Inconel 751 47 0.9 30 60 to 100 2,4,6 - F, SR, T
[7] Cryogenic cooling Ti-6Al-4V alloy 15,20,25 3,9,15 5,15,25 - - - F, SR
[29] Dry, soluble oil, cryogenic Stainless steel 316 31.4 6,7.5,9 10,20,30,40 - 3,4,5 40 SR,F,SE
[30] Dry, Wet and Cryogenic Carbon steel 1045 23 0.4 20 1.13,0.13 - - RS,M,H,SM
[31] MQCL with CO2 cryogen GGG70 cast iron 30 - 10 - - SR,F,SE
[32] Soluble oil and Cryo-cooling MS, HCS, die steel 23.5 8 10 to 40 - - - F,SR,RS,T
[33] Dry, Wet and Cryo-cooling AISI 304 stainless steel 30 9 3 - - - RS,SM,SR,
P – Grinding power, F – Grinding forces, SR – Surface roughness, SM – Surface morphology, CM – Chip morphology, T – Temperature, H – Hardness, RS – Residual stress, M – Microstructure, SE – Specific energy, µ - Coefficient of friction,
MRR-Material removal rate, RE – Roundness error, G – Grinding ratio, L - Subsurface damage length, WL – Wheel loading, W- Wheel wear

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2. Material and methods
The age hardened IN-718 with the dimensions of length, width and height of 70 mm, 10 mm, and 60 mm
respectively has been used as a work-material in surface grinding experiments. The detailed elemental
constituents of IN-718 samples used in the present experimentation is given in Table 3. The grinding experiments
have been performed at 20 m/s wheel speed, 9 m/min table speed and 15 microns depth of cut using vitrified
bonded white alumna wheel of specification WA60K5V. The mean values of the responses obtained after three
replications have been reported. Surface grinding experiments have been conducted on the SMART-H1224II CNC
surface grinder under dry, FCT, MQCL and cryogenic environments. Normal and tangential grinding forces have
been measured online using Kistler 9257B piezoelectric dynamometer. This dynamometer was attached to
5070A, Kistler charge amplifier and DynoWare data acquisition software. For FCT and MQCL experiments soluble
oil, a mixture of water and Castrol mineral oil in 30:1 ratio has been used. The mixture of water and oil provides
both good cooling and lubricating properties as required in the grinding process. The effectiveness of MQCL
primarily depends upon the atomization of liquid droplets. The optimised parameters of MQCL by Sinha et al.
[34] has been used the MQCL experiments. The optimised MQCL parameters are 150 ml/h flow rate, 8 bar air
pressure and intermediate nozzle position. In cryogenic grinding, liquid nitrogen jet has been injected pointed
towards cutting zone through the nozzle orifice of 1 mm diameter. The MQCL and cryogenic setups used in the
experiments are shown in Figure 1. The specific energy (U) requirement (J/mm3) has been theoretically
calculated using the following relation [35]
60  F  V
U t c ………………………………………………………….. (i),
V bd
w
where Ft, Vc, Vw, b, d are the mean tangential force (N), wheel speed (m/s), table speed (m/min), width of
workpiece (mm), and depth of cut (microns) respectively.

Table 3 Percentage chemical composition of IN-718 samples used.

Element Ni Cr Nb Mo Ti Al C S Cu Fe
Weight (%) 53.12 17.65 4.79 3.07 0.86 0.60 0.04 0.03 0.02 18.63

Figure 1. Experimental setups for (a) MQCL and (b) cryogenic grinding experiments.

SEM tests of the grinding chips obtained during dry, FCT, MQCL and cryogenic conditions have been carried
out using ZEISS EVO 50 Series Scanning Electron Microscope. For SEM and EDX tests, grinding chips were
collected on carbon tape while performing experiments dry, FCT, MQCL and cryogenic environments. The
collected grinding chips were completely dried before the SEM and EDX examinations. These studies have been
conducted to assess the effect of high heat generated in the grinding zone under different grinding mediums.

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3. Results and discussions
The ability to predict grinding forces and specific energy consumption are very important aspects of grinding
process. The forces generated in grinding greatly contribute to the quality of finished products. As discussed in
the earlier sections, grinding forces generated during the grinding process, SEM and EDX study have been carried
out to study the grindability aspects of IN-718. In this work mean of three passes has been calculated and being
reported for both normal and tangential forces. From the measured tangential force, specific grinding energy
has been calculated using equation (i) for all cases.
3.1 Variation in grinding forces
The magnitude of the tangential force acting in grinding direction is an important indicator of grindability of
the material. Moreover, it has the vital role in the estimation of specific power and specific energy consumption
in grinding. High tangential forces cause high heat generation and thermal damage. Normally in grinding process
analysis, the magnitude of the tangential force is the key indicator of the degree of difficulty associated with a
material in grinding under prescribed grinding condition. From Figure 2, it can be noticed that tangential forces
in MQCL and cryogenic grinding are smaller than those obtained in dry and FCT grinding, however in cryogenic
grinding it has been found to be least. It may be due to good lubricity between the mating surfaces due to
lubricating film formation along the wheel periphery, which further assists in improving the slipping of grains
over the work surface [35]. Smaller tangential force further aids in retaining the sharpness of grains for longer
duration resulting in lesser heat generation. At a lower temperature in cryogenic grinding, the grains retain their
sharpness for a longer duration and, therefore, resulting in lower grinding forces and eventually culminates in
increased wheel life [7, 32]. From this, it can be established that such grinding condition leads to lesser power
consumption resulting in lower heat generation that is one of the favourable conditions for grinding.
Normal force variations in dry, FCT, MQCL and cryogenic with wheel speed, table speed and depth of cut is
shown in Figure 3. From Figure 3, it can be comprehended that normal forces are lower in MQCL grinding
compared with FCT grinding whereas in cryogenic grinding they are always smaller. Smaller normal force
signifies the ease of indentation which eventually results in easy grinding. The application of soluble oil in MQCL
mode and cryogenic significantly reduce normal force component reflecting the retention of grits sharpness for
a longer duration due to a reduction in grinding zone temperature resulting lesser wheel wear [7]. In dry and
FCT, normal grinding forces are higher compared to MQCL and cryogenic grinding that can cause erratic part
tolerance and self-induced vibration, also known as chatter.

Figure 2. Variation in tangential forces. Figure 3. Variation in normal forces.

3.2 Variation in specific grinding energy

Specific energy is one of the prime indices reflecting the grinding easiness. Moreover, it also reflects
the energy consumption and further heat generation while grinding. From Figure 4, it is evident that specific
energy requirement is highest in dry grinding and least in cryogenic grinding whereas, in FCT and MQCL, these
are almost comparable. Larger tangential force while dry grinding resulted in high specific energy requirement
which can be assigned to the fact of the thermal damages of the alumina abrasives forming wear flattening. In
MQCL and cryogenic grinding the lower energy consumption are due to preferably easy material shearing
culminating in lower tangential forces.

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 Figure 4. Variation in specific grinding energy under different grinding mediums.
3.3 Grinding chip characterisation
The SEM micrographs and EDX analysis of the grinding chips collected under different grinding
environments are being provided in the Figures 5 and 6 respectively. From Figure 5, it is clear that in dry grinding
almost complete curling of chips observed, which provides sufficient hints for a high heat generation. This is also
supported by the highest amount of oxygen found in case of dry chips. In case of MQCL and cryogenic grinding,
chip sizes are relatively smaller caused by chip breakage due to high cooling effect. Such cooling produces almost
breakage of the chip from the middle and produces C type chips whereas in FCT grinding chip size lies in between
dry and cryogenic grinding. EDX analysis has been conducted for the grinding chips obtained during grinding
with dry, MQCL and cryogenic conditions. The percentage elemental composition for each of these samples is
listed in Table 4. SEM images with a graphical depiction of percentage weight of constituent elements for these
grinding chips are given in Figure 6. Nickel percentage decreased from 19.72, 15.02, 6.47 from cryogenic chips,
MQCL chips and dry chips, which is a clear indication of the formation of nickel compounds primarily due to
relatively larger heat generation in the grinding area. From the data in Table 4, it can be seen that oxygen
percentage decreased from dry chips: 28.60, MQCL chips: 17.42 and cryogenic chips: 11.36 respectively. The
percentage rise in the oxygen content in dry grinding chips indicates severe oxidation over the ground surface.
Similarly, the chromium percentage in dry chips are relatively less which could be due to the formation of
chromium oxide (Cr2O3) formation at a higher temperature.

Figure 5. Grinding chips SEM micrographs under (a) dry, (b) FCT, (c) MQCL, and (d) cryogenic conditions.

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 Figure 6. Grinding chips EDX analysis under (a) dry, (b) MQCL, and (d) cryogenic conditions.

Table 4 Elemental composition of ground chips collected under dry, MQCL and cryogenic grinding.

Weight (%)
Elements
Dry grinding MQCL grinding Cryogenic grinding

Nickel 6.47 15.02 19.72

Oxygen 28.60 17.42 11.36

Carbon 53.39 50.27 48.65

Iron 4.69 6.75 7.49

Chromium 3.12 5.92 5.24

Niobium 0.59 1.52 1.18

Molybdenum 0.81 0.57 1.91

Titanium 0.68 0.93 -

Aluminum 0.63 0.44 0.73

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4. Conclusions
The present work is an attempt to investigate the grinding responses of IN-718 under different grinding
environments. The grinding characterisation has been investigated experimentally by evaluating grinding forces,
specific grinding energy, SEM and EDX test of grinding chips. From this work, main conclusions can be
summarised as:
1. In dry grinding, grinding forces have been found to be always larger which indicate the wear flattening of
the grits due to high-temperature generation causing intense surface oxidation of IN-718.
2. From EDX analysis of the grinding chips obtained under dry, MQCL, and cryogenic conditions, it is also clear
that on the grinding chips, the percentage of oxygen increased from 11.36 to 28.60, which is a clear
indication of surface oxidation in the case of dry grinding.
3. The cryogenic environment provides a significant reduction in grinding forces, specific energy and hence in
grinding zone temperature, which consequently promotes favourable grit- surface interactions. Moreover,
the inert nature of cryogenic provides cooling and lubrication without damaging the ground surface. This
argument is also supported by least oxygen percentage found in case of ground surface and grinding chips
obtained in cryogenic grinding.
4. In MQCL grinding, lower tangential force and specific grinding energy have been observed, which indicates
favourable grinding condition as compared to dry grinding. MQCL can be a promising alternative in IN-718
grinding which not only enhances the process efficacy but can significantly reduce the allied manufacturing
costs by lowering the cutting fluid consumption.
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