Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy

Yusuf Siyambaş; Aslan Akdulum

Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy

Abstract

Hastelloy X superalloy, which exhibits superior performance under harsh conditions such as extreme temperature, oxidation, and corrosion, is widely used in the aviation and energy sectors but causes significant problems in machining due to its difficult machinability properties. This situation has brought up the need for alternative cooling strategies to reduce cutting forces and temperatures during machining, improve surface quality, and minimize environmental impacts. In this research, the impacts of varying cutting variables (depth of cut, feed rate, and cutting speed) on cutting force (FR), surface roughness (Ra), and cutting temperature (T) in the turning of Hastelloy X superalloy under three different machining environments (dry, vortex air, and compressed air) were experimentally investigated. The Taguchi L9 orthogonal layout was utilized for the experimental design, and simultaneous optimization of multiple performance outcomes was carried out by the grey relational analysis (GRA) technique. According to the findings, the lowest FR and Ra occurred in dry, compressed air and vortex air processing environments, respectively. The lowest values in terms of T were obtained in compressed air, vortex air, and dry machining environments, respectively. In summary, the effect of cooling conditions on T was not reflected in FR and Ra. As a result of GRA optimization, where all performance criteria were evaluated together, the most suitable machining condition was determined to be a dry machining environment, an 80 m/min cutting speed, a 0.075 mm/rev feed rate, and a 0.8 mm cutting depth. Vortex air and compressed air environments have been evaluated as a strong alternative to dry environments.

Keywords

References

[1] A. Altin, “Optimization of the turning parameters for the cutting forces in the Hastelloy X superalloy based on the Taguchi method,” Materials and technology, vol. 48, no. 2, pp. 249–254, 2014. [2] M. S. Alsoufi and S. A. Bawazeer, “Predictive Modeling of Surface Integrity and Material Removal Rate in Computer Numerical Control Machining: Effects of Thermal Conductivity and Hardness,” Materials (Basel), vol. 18, no. 7, 2025. doi: 10.3390/ma18071557
[3] H. Hegab and H. A. Kishawy, “Towards sustainable machining of inconel 718 using nano-fluid minimum quantity lubrication,” Journal of Manufacturing and Materials Processing, vol. 2, no. 3, 2018. doi: 10.3390/jmmp2030050
[4] K. Venkatesan, S. Devendiran, K. Nishanth Purusotham, and V. S. Praveen, “Study of machinability performance of Hastelloy-X for nanofluids, dry with coated tools,” Materials and Manufacturing Processes, vol. 35, no. 7, pp. 751–761, 2020. doi: 10.1080/10426914.2020.1729990
[5] T. B. Oschelski, W. T. Urasato, H. J. Amorim, and A. J. Souza, “Effect of cutting conditions on surface roughness in finish turning Hastelloy® X superalloy,” Materials Today: Proceedings, vol. 44, pp. 532–537, 2021. doi: 10.1016/j.matpr.2020.10.211
[6] V. Sivalingam, J. Sun, S. K. Mahalingam, L. Nagarajan, et al., “Optimization of process parameters for turning hastelloy x under different machining environments using evolutionary algorithms: A comparative study,” Applied Sciences, vol. 11, no. 20, pp. 1–18, 2021. doi: 10.3390/app11209725
[7] Q. Zhou, V. Sivalingam, J. Sun, P. K. Murugasen, et al., “Understanding the machining induced tribological mechanism of Hastelloy-X under sustainable cooling/lubrication conditions,” The International Journal of Advanced Manufacturing Technology, vol. 123, no. 3–4, pp. 973–983, 2022. doi: 10.1007/s00170-022-10243-x
[8] R. L. de Paiva, R. de Souza Ruzzi, L. R. de Oliveira, E. P. Bandarra Filho, et al., “Experimental study of the influence of graphene platelets on the performance of grinding of SAE 52100 steel,” The International Journal of Advanced Manufacturing Technology, vol. 110, no. 1–2, pp. 1–12, 2020. doi: 10.1007/s00170-020-05866-x
[9] A. Race, I. Zwierzak, J. Secker, J. Walsh, et al., “Environmentally sustainable cooling strategies in milling of SA516: Effects on surface integrity of dry, flood and MQL machining,” Journal of Cleaner Production, vol. 288, p. 125580, 2021. doi: 10.1016/j.jclepro.2020.125580

[10] S. Yaqoob, J. A. Ghani, A. Z. Juri, S. S. Muhamad, et al., “A review of sustainable hybrid lubrication (Cryo-MQL) techniques in machining processes,” The International Journal of Advanced Manufacturing Technology, vol. 131, no. 1, pp. 151–169, 2024. doi: 10.1007/s00170-024-13135-4
[11] S. H. Ali, Y. A. O. Yu, W. U. Bangfu, Z. H. A. O. Biao, et al., “Recent developments in MQL machining of aeronautical materials: A comparative review,” Chinese Journal of Aeronautics, vol. 38, no. 1, p. 102918, 2024. doi: 10.1016/j.cja.2024.01.018
[12] C. Courbon, L. Sterle, M. Cici, and F. Pusavec, “Tribological effect of lubricated liquid carbon dioxide on TiAl6V4 and AISI1045 under extreme contact conditions,” Procedia Manufacturing, vol. 47, pp. 511–516, 2020. doi: 10.1016/j.promfg.2020.04.139
[13] S. Polo, E. M. Rubio, M. M. Marín, and J. M. Sáenz de Pipaón, “Evolution and Latest Trends in Cooling and Lubrication Techniques for Sustainable Machining: A Systematic Review,” Processes, vol. 13, no. 2, 2025. doi: 10.3390/pr13020422
[14] D. Gürkan, S. A. Yaşar, G. Uzun, and İ. Korkut, “Vorteks SoğutmYöntemi̇ni̇n Talaşlı İmalat Yöntemleri ve Kesme Parametreleri̇ne Göre İncelenmesi̇,” Gazi University Journal of Science Part C: Design and Technology, vol. 8, no. 3, pp. 730–745, 2020. doi: 10.29109/gujsc.727746
[15] Y. Özçatalbaş and A. Baş, “Tornalamada hava püskürtme ile soğutmanın kesme kuvvetleri ve takım ömrüne etkilerinin araştırılması,” Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, vol. 21, no. 3, 2013.
[16] Y. Siyambaş and A. Akdulum, “Prediction of surface roughness using different features in vortex cooled turning process of Ti6Al4V alloy,” Measurement, vol. 237, 2024. doi: 10.1016/j.measurement.2024.115258
[17] A. Díaz-Álvarez, J. Díaz-Álvarez, J. L. Cantero, and M. H. Miguélez, “Using Carbide Tools : Haynes 282 and Inconel 718 Comparison,” Metals, vol. 11 no. 12, 2021. doi.org/10.3390/met11121916
[18] M. A. Sofuoğlu, F. H. Çakır, S. Gürgen, S. Orak, et al., “Experimental investigation of machining characteristics and chatter stability for Hastelloy-X with ultrasonic and hot turning,” The International Journal of Advanced Manufacturing Technology, vol. 95, no. 1–4, pp. 83–97, 2018. doi: 10.1007/s00170-017-1153-9
[19] Y. Siyambaş and Y. Turgut, “Experimental and statistical investigation of mechanical properties and surface roughness in additive manufacturing with selective laser melting of AlSi10Mg alloy,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 45, no. 10, pp. 1–15, 2023. doi: 10.1007/s40430-023-04445-x
[20] A. Akdulum and Y. Kayir, “Experimental investigation and optimization of process stability in drilling of Al 7075-T651 using indexable insert drills,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 45, no. 8, pp. 1–20, 2023. doi: 10.1007/s40430-023-04303-w
[21] S. Yağmur, “The effects of cooling applications on tool life, surface quality, cutting forces, and cutting zone temperature in turning of Ni-based Inconel 625,” The International Journal of Advanced Manufacturing Technology, vol. 116, no. 3–4, pp. 821–833, 2021. doi: 10.1007/s00170-021-07489-2
[22] R. Çakıroğlu and M. Günay, “Comprehensive analysis of material removal rate, tool wear and surface roughness in electrical discharge turning of L2 tool steel,” Journal of Materials Research and Technology, vol. 9, no. 4, pp. 7305–7317, 2020. doi: 10.1016/j.jmrt.2020.04.060
[23] R. Çakıroğlu, “Analysis of Ranque–Hilsch vortex tube cooling performance in respect of cutting temperature, resultant cutting force and chip morphology in turning of BeCu alloy,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 44, no. 8, pp. 1–18, 2022. doi: 10.1007/s40430-022-03689-3
[24] A. Anurag, R. Kumar, K. K. Joshi, and R. K. Das, “Analysis of Chip Reduction Coefficient in Turning of Ti-6Al-4V ELI,” Materials science and engineering, vol. 390, no. 1, 2018. doi: 10.1088/1757-899X/390/1/012113
[25] K. V. Sudhakar, J. C. Cisneros, H. Cervantes, and C. G. Pineda, “Machining characteristics and fracture morphologies in a copper-beryllium (Cu-2Be) alloy,” Journal of materials engineering and performance, vol. 15, no. 1, pp. 117–121, 2006. doi: 10.1361/105994906X83510
[26] M. Akgün and H. Demir, “Experimental and numerical analysis of the effect of cutting parameters on cutting force and chip formation in turning process,” El-Cezeri,, vol. 8, no. 2, pp. 897–908, 2021. doi: 10.31202/ecjse.892705
[27] S. Ehsan, S. A. Khan, and M. Rehman, “Defect-free high-feed milling of Ti-6Al-4V alloy via a combination of cutting and wiper inserts,” The International Journal of Advanced Manufacturing Technology, vol. 114, no. 1–2, pp. 641–653, 2021. doi: 10.1007/s00170-021-06875-0
[28] T. Ding, S. Zhang, Y. Wang, and X. Zhu, “Empirical models and optimal cutting parameters for cutting forces and surface roughness in hard milling of AISI H13 steel,” The International Journal of Advanced Manufacturing Technology, vol. 51, no. 1–4, pp. 45–55, 2010. doi: 10.1007/s00170-010-2598-2
[29] S. Yağmur, “Investigation of the effect of minimum quantity lubrication and Ranque–Hilsch vortex tube cooling on cutting forces, surface roughness and cutting zone temperature in turning Al 6082 T4 alloy,” Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2023. doi: 10.1177/09544089231209007
[30] R. Çakiroǧlu and A. Acir, “Optimization of cutting parameters on drill bit temperature in drilling by Taguchi method,” Measurement, vol. 46, no. 9, pp. 3525–3531, 2013. doi: 10.1016/j.measurement.2013.06.046
[31] M. C. Shaw and J. O. Cookson, Metal cutting principles, New York Oxford University Press, vol. 2–3, 2005.
[32] J. S. Hu, D. X. Liu, Y. Z. Liu, C. X. Yue, et al., “Experimental investigation on air cooling of GCr15”. Key Engineering Materials, vol. 375, pp. 197-200, 2008. doi.org/10.4028/www.scientific.net/KEM.375-376.197
[33] Z. Taha, H. A. Salaam, T. T. Ya, S. Y. Phoon, et al., “Vortex tube air cooling: The effect on surface roughness and power consumption in dry turning”. International Journal of Automotive and Mechanical Engineering, vol. 8, pp. 1477-1586, 2013. doi: 10.15282/ijame.8.2013.34.0122
[34] A. Kaçal, “Effect of machining parameters on turning of Inconel X750 using PVD coated carbide inserts.” Journal of Scientific & Industrial Research, vol. 79 no. 3, pp. 226-231, 2022.

Details

Primary Language

English

Subjects

Optimization Techniques in Mechanical Engineering

Journal Section

Research Article

Authors

Yusuf Siyambaş ^*
0000-0001-8360-5213
Türkiye

Aslan Akdulum
0000-0003-2030-3167
Türkiye

Publication Date

August 31, 2025

Submission Date

April 26, 2025

Acceptance Date

July 27, 2025

Published in Issue

Year 2025 Volume: 11 Number: 2

IZ

https://izlik.org/JA35UK68DY

Cite

RIS / Bibtex

APA

Siyambaş, Y., & Akdulum, A. (2025). Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy. Gazi Journal of Engineering Sciences, 11(2), 243-253. https://izlik.org/JA35UK68DY

AMA

1.Siyambaş Y, Akdulum A. Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy. GJES. 2025;11(2):243-253. https://izlik.org/JA35UK68DY

Chicago

Siyambaş, Yusuf, and Aslan Akdulum. 2025. “Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy”. Gazi Journal of Engineering Sciences 11 (2): 243-53. https://izlik.org/JA35UK68DY.

EndNote

Siyambaş Y, Akdulum A (August 1, 2025) Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy. Gazi Journal of Engineering Sciences 11 2 243–253.

IEEE

[1]Y. Siyambaş and A. Akdulum, “Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy”, GJES, vol. 11, no. 2, pp. 243–253, Aug. 2025, [Online]. Available: https://izlik.org/JA35UK68DY

ISNAD

Siyambaş, Yusuf - Akdulum, Aslan. “Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy”. Gazi Journal of Engineering Sciences 11/2 (August 1, 2025): 243-253. https://izlik.org/JA35UK68DY.

JAMA

1.Siyambaş Y, Akdulum A. Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy. GJES. 2025;11:243–253.

MLA

Siyambaş, Yusuf, and Aslan Akdulum. “Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy”. Gazi Journal of Engineering Sciences, vol. 11, no. 2, Aug. 2025, pp. 243-5, https://izlik.org/JA35UK68DY.

Vancouver

1.Yusuf Siyambaş, Aslan Akdulum. Multi-Criteria Performance Analysis of Dry, Vortex Air and Compressed Air Environments in Turning Hastelloy X Superalloy. GJES [Internet]. 2025 Aug. 1;11(2):243-5. Available from: https://izlik.org/JA35UK68DY