Life cycle and machinability analysis of milling Incoloy 286 using sustainable cooling/lubrication technologies

The current study scrutinized the machinability and techno-economics of milling Incoloy 286. The influence of cutting parameters and cooling method on various machining outputs was examined. Cryogenic conditions enhanced tool life by up to 70.73%, with MQL (53.33%) and flood cooling (44.44%) following closely behind. Cryogenic conditions lowered flank wear by up to 26.87%, followed by MQL (10.71%) and flood cooling (9.38%). Additionally, for all parameters except vc = 100 m/min and f = 0.1 mm/rev, the overall machining costs are as follows: cryogenic (LN2) < MQL < Flood < Dry. While expenses increased during dry milling, when MQL and cryogenic methods were applied, insert costs reduced by 70-135% when compared to dry milling. Furthermore, carbon emissions (CE) values increased by 50-85% when MQL and cryogenic cutting conditions were used versus flood machining. Total emissions are in the following order: MQL, Dry, Cryogenic, and Flood. In dry, MQL, and cryogenic cutting circumstances, the [CE]_CIF typically ranged from 8 to 27%. However, flood cooling had a significantly higher [CE]_CIF of 53-57%. As compared to dry milling, cryogenic cooling reduced emissions owing to power consumption by 11-39%.