Holistic life cycle assessment of drilling Incoloy 825 utilizing versatile consumption of fluids: a sustainability perspective
Authors :- Hussain S.; Zhao G.; Khan A.M.; Khanna N.; Lotwala T.; Khan A.; Jamil M.; He N.
Publication :- International Journal of Advanced Manufacturing Technology, Springer, 2025
Nickel-based superalloys are classified as difficult-to-cut materials due to their high strength, toughness, cold work hardening, and low thermal conductivity, leading to chip adhesion, accelerated tool wear, and high cutting forces. In the meantime, high cutting forces and built-up edges increase the power consumption and corresponding carbon emission. Establishing a sustainable production process that maintains a balance between economic feasibility and ecological preservation is among the existing challenges of manufacturing sectors. Dry machining operations are good in terms of environment, but not perfectly alternatives to sustainable manufacturing. Clean and sustainable manufacturing requires a balance between quality, productivity, and machine tool energy demand. The current study compares the machinability and sustainability perspectives of drilling Incoloy 825 by employing cryogenic liquid carbon dioxide (LCO2) and minimum quantity lubrication (MQL) under internal and external lubri-cooling technologies. The drilling performance measures are based on responses and parameters such as thrust force, surface roughness, power consumption, tool wear, and life cycle assessment (LCA) at six levels of cutting speed. The experimental findings underscored that internal cryogenic LCO2 was not feasible as most of the cutting tools prematurely ruptured inside the holes as a result of the cutting lips’ overcooling. The hybrid Cryo-MQL (CO2 continuous external, internal MQL) allowed to drill maximum number of holes because of superior cooling lubrication constrained premature tool failure. Therefore, compared to dry cutting, Cryo-MQL reduced surface roughness by 3.24%, thrust force by 16.8%, and power consumption by 20.6%, respectively. In addition, LCA was implemented by using ReCiPe 2016 midpoint (H) method to evaluate the impact of cooling/lubrication on human health, aquatic life, natural resources, and the environment. LCA results indicated superior machinability and lower power consumption with Cryo-MQL but a high impact on environment and operator health.