Title: Tool wear and surface integrity in the cryogenic cutting of high entropy alloy Ni40Fe30Co20Al10

Authors: Xiaoxia Zhang; Lihu Wang; Yang Qiao; Xiuli Fu; Guoliang Liu; Xiangyu Wang

Addresses: School of Mechanical Engineering, University of Jinan, 336 West Nanxinzhuang Road, 250022, Jinan, Shandong, China ' School of Mechanical Engineering, University of Jinan, 336 West Nanxinzhuang Road, 250022, Jinan, Shandong, China ' School of Mechanical Engineering, University of Jinan, 336 West Nanxinzhuang Road, 250022, Jinan, Shandong, China ' School of Mechanical Engineering, University of Jinan, 336 West Nanxinzhuang Road, 250022, Jinan, Shandong, China ' School of Mechanical and Automotive Engineering, Qingdao University of Technology, 11 Fushun Road, 266520, Qingdao, Shandong, China ' School of Mechanical Engineering, University of Jinan, 336 West Nanxinzhuang Road, 250022, Jinan, Shandong, China

Abstract: High entropy alloys exhibit exceptional mechanical properties but present machinability constrains. This study investigates the effect of cutting speeds (100/200/300 m/min) and cooling conditions on tool wear mechanisms and surface integrity during the cutting of Ni40Fe30Co20Al10 HEA. Experimental results demonstrate that cryogenic cooling generates higher cutting forces than dry and emulsion cooling. Under different cutting parameters, the rake face of the tool was mainly cratering wear and the flank wear was mainly adhesive. Compared with dry cutting and emulsion cooling cutting, cryogenic cutting inhibited tool wear. After cutting, the workpiece surface retains a face-centred cubic (FCC) structure, with cryogenic cooling promoting grain refinement and reducing surface roughness. Observed surface defects include material adhesion, feed marks, and micro-pits. Overall, Cryogenic cutting significantly mitigated cutting heat, resulting in reduced temperatures during the machining process. This method promoted uniform material deformation, minimised tool wear, and enhanced the overall quality of the machined surface.

Keywords: cryogenic cutting; high entropy alloys; tool wear; grain refinement; surface integrity.

DOI: 10.1504/IJMMS.2025.148934

International Journal of Mechatronics and Manufacturing Systems, 2025 Vol.18 No.1, pp.1 - 20

Received: 24 Feb 2025
Accepted: 30 May 2025
Published online: 04 Oct 2025 *

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