Evaluation of flank wear of a self-propelled rotary tool during turning using nanofluid under MQL

Inconel 718, a heat-resistant nickel alloy, is employed in aerospace, marine, and defence applications due to its unique properties. However, these alloys are difficult to cut due to their low heat conductivity and proclivity for work-hardening. With a focus on sustainability, ongoing efforts are underway to enhance the manufacturability of these alloys. This study assesses the flank wear progression of a self-propelled rotary tool (SPRT) while turning Inconel 718 using a hybrid nanofluid under minimum quantity lubrication (NFMQL) conditions. To create a hybrid nanofluid, multi-walled carbon nanotubes (MWCNTs) and aluminium oxide (Al2O3) nanoparticles were mixed with 0.25% in a commercially available palm oil. Experiments were carried out by changing the process parameters. Flank wear was monitored and analysed with digital and electron microscopes. Experimental-based models were created to analyse and compare the influence of cutting conditions and machining time on SPRT flank wear under NFMQL conditions. Additionally, an ANN model is created to predict how flank wear will change over time. To provide precise forecasts, the ANN model makes use of past tool wear rate data. Lastly, the processes of tool wear for SPRTs under NFMQL are investigated.