Open Access

Evaluating the Influence of Eco-friendly Cryogenic Coolants on Hole Parameters in Deep Hole Drilling of Inconel 718 Alloy

J. Elanchezhian, Department of Mechanical Engineering, Anand Institute of Higher Technology, Chennai, TN, India A. Thanikasalam, Department of Maritime Studies, Academy of Maritime Education and Training, Chennai, TN, India B. Arul Kumar, Department of Mechanical Engineering, Jerusalem College of Engineering, Chennai, TN, India P. Thamizhvalavan, Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai, TN, India M. Thiyagu, thiyagu1080@gmail.com
Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai, TN, India P. Murali Department of Mechanical Engineering, Anand Institute of Higher Technology, Chennai, TN, India

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Abstract

Deep hole drilling is a complex process, especially with heat-generating high-strength alloys like Inconel 718. Key challenges include heat management and effective chip removal to preserve tool life, hole accuracy, and surface finish. This method is ideal for applications like gun barrels, fuel lines, lubricant channels, and aircraft components. While cutting fluids cool and lubricate, they can cause health issues. Cryogenic coolants offer an eco-friendly, safer alternative that enhances machining performance. This study constitutes an experimental investigation of deep-hole drilling processes performed on a GUNDRILL CNC machine. The primary objective is to establish a comprehensive understanding of the interplay between cutting speed, feed rate, and various coolants concerning key performance indicators, including surface roughness, hole wall temperature, hole quality, material removal rate and tool wear. The coolants considered in this study encompass traditional cutting oil, cryogenic liquid nitrogen (LN₂), and carbon dioxide (CO₂) in cryogenic form. The use of cryogenic LN₂ coolant during Inconel 718 machining led to a significant reduction in hole wall temperature compared to wet and cryogenic CO₂ deep-hole drilling. This was due to the low temperature of LN₂, which allowed efficient heat dissipation from the contact zone. LN₂ also improved surface roughness by 29-55% compared to traditional oil coolant and 22-39% compared to cryogenic CO₂ cooling. Additionally, cryogenic LN₂ cooling decreased circularity error by 12-22% compared to oil coolant and 8-21% compared to cryogenic CO₂ conditions. The cryogenic LN₂ coolant enhanced chip breakability and extended tool life without damaging the cutting-edge insert.

 

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