Kaushal Prasad, Arpita Roychoudhury, Ganesh Prasad Shukla | International Journal of Manufacturing and Materials Processing | Vol 11, Issue 1 | pp. 1-7 | ISSN: 2582-5046
Abstract
Abstract
Sustainable machining is crucial for minimizing the environmental, economic, and social challenges
associated with modern manufacturing. This study reviews environmentally sustainable machining
approaches including dry machining, Minimum Quantity Lubrication (MQL), and cryogenic cooling,
and evaluates their effects on machining performance and sustainability. Key performance indicators,
such as surface integrity, tool wear, energy efficiency and cutting forces, are analyzed across various
materials. The findings demonstrate that dry machining eliminates liquid waste but is often limited by
tool wear and heat-related challenges, especially in difficult-to-machine materials, such as titanium
and nickel alloys. MQL machining, which applies minimal oil mist for lubrication, significantly reduces
cutting forces (10–30%), improves surface finish (91%), and extends tool life (267%), making it ideal
for hardened steels and aluminum alloys, Cryogenic machining, utilizing LN2 or CO2 cooling, provides
superior thermal control, extending tool life by 80–200% and reducing cutting temperatures by up to
75%, particularly for nickel-based superalloys and aerospace applications. Hybrid methods, such as
combining cryogenic cooling with MQL, further enhance machining efficiency and environmental
sustainability. The study concludes that there is not a single superior machining technique, but that
hybrid machining solutions combining cryogenic cooling with MQL are the most viable ones for
sustainable, high-performance machining. This review underscores the potential for integrating
advanced techniques to achieve cleaner and more efficient machining processes.
Keywords:Sustainable machining, dry machining, eco-friendly machining, minimum quantity
lubrication (MQL), tool wear reduction.
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