In the face of the world’s population growth and ensuing demands, the industrial
sector assumes a crucial role in the management of limited energy supplies.
Superalloys based on nickel, which are well-known for their remarkable
mechanical qualities and resilience to corrosion, are now essential in vital
applications like rocket engines, gas turbines, and aviation. However, these
metals’ toughness presents a number of difficulties during machining operations,
especially with regard to power consumption. This abstract explores the
variables that affect power consumption during the machining of superalloys
based on nickel in great detail and suggests ways to improve energy efficiency
in this area. The effects of important variables on power consumption are
extensively investigated, including cutting speed, feed rate, depth of cut, tool
geometry, and cooling/lubrication techniques. A careful balance between these
factors is necessary to maximize machining efficiency and reduce power usage.
Furthermore, this study reviews the effect of different heat source applications
on power consumption and the resultant quality of machined nickel-based
superalloys. Additionally, the critical role of cooling and lubrication in
mitigating the adverse effects of high temperatures generated during machining
is thoroughly examined. Innovative cooling strategies, including cryogenic or
high-pressure coolant systems, are explored as potential avenues to enhance heat
dissipation and minimize power requirements. In essence, this abstract not only
sheds light on the challenges inherent in machining nickel-based superalloys but
also offers actionable insights into how energy efficiency can be maximized
through strategic parameter optimization and the adoption of innovative cooling
techniques. By addressing these aspects, manufacturers can effectively navigate
the complexities of machining superalloys while minimizing their environmental
footprint and operational costs.
