Akademik Veri Yönetim Sistemi
TRIBOLOGY INTERNATIONAL, cilt.221, ss.112015, 2026 (SCI-Expanded, Scopus)
This study elucidates the tribological interactions and wear mechanisms at the tool-chip interface during the milling of Powder Bed Fusion (PBF) additively manufactured (AMed) Ti6Al4V alloy. The synergistic effects of a hybrid cooling-lubrication strategy combining CO₂ cryogenic cooling with Al₂O₃-based nanofluid minimum quantity lubrication (nanoMQL) were investigated under dry, mono-cryogenic, and mono-nanoMQL environments. Milling experiments were conducted at two cutting speeds (100 and 150 m/min) to assess the influence of thermal and mechanical loads on tool degradation. Tool wear was evaluated through quantitative measurements and characterized via scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) to reveal dominant wear modes. Results show that the hybrid nanoMQL + CO₂ strategy provided the most effective wear suppression, reducing flank wear by up to 38.97% compared to cryogenic cooling and 26.5% compared to dry machining at 100 m/min. While nanoMQL alone also demonstrated considerable improvements in tool life by enhancing both cooling and lubrication, CO₂ only cooling, despite its thermal control capabilities, induced brittle wear mechanisms due to the suppression of thermal softening. Increasing the cutting speed amplified tool wear across all conditions, with dry machining at 150 m/min exhibiting the highest wear rate due to intensified thermal and mechanical stresses. SEM and EDX analyses revealed built-up edge (BUE) and built-up layer (BUL) formation, notching, chipping, and fracture as the primary wear mechanisms, which varied significantly with cooling–lubrication strategy. The hybrid environment minimized adhesive layer formation and suppressed thermally activated diffusion, thereby preserving cutting edge integrity. These findings underscore the potential of hybrid cooling-lubrication techniques in enhancing machining performance of AMed Titanium alloys and contribute to the development of more sustainable and efficient manufacturing strategies.