Drilling performance of Nickel-based Hastelloy C276 under mono and hybrid nanofluids environments

Abstract

The use of sustainable techniques could significantly improve the machining performance of difficult-to-machine materials such as Ni-based Hastelloy C276. Therefore, in this research work mono and hybrid nanofluids-based mist cooling techniques have been employed for the drilling of Hastelloy C276. Different concentrations of graphene and Al2O3 nanoparticles have been used for the preparation of mono and hybrid nanofluids. As per the contact angle analysis, all the cutting fluids have been found to have good wettability with the WC substrate. Massive fracture over the chisel edge has been observed during the experiment under dry condition. As compared to both dry and mono Al2O3 conditions, the use of graphene-based mono and hybrid nanofluids resulted in stable cutting edge condition. The application of graphene nanoparticles significantly reduced the adhesion over the chisel edge. As compared to dry mode, a maximum 40 % reduction in the cutting force value was recorded under the hybrid cutting fluid condition. The combination of interlayer shearing and the rolling mechanisms is responsible for such a reduction in the cutting force. The synergistic effect of graphene and alumina present in the hybrid fluid also significantly reduced the surface roughness of the inner surface of the hole. The SEM analysis has revealed that the use of hybrid nanofluid improved the inner surface morphology of the drilled holes by eliminating the adhesion and scratch marks formation. � 2024 The Society of Manufacturing Engineers