Integrating textured tools and diverse lubricooling approaches in machining performance of Ti and Ni-base alloys – a comprehensive review

Manufacturers confront considerable difficulties when machining titanium and nickel-based alloys due to concerns related to surface integrity, tool wear, cutting forces and temperature regulation. In order to tackle these difficulties, the prevailing method consists of utilizing cutting fluids to cool and lubricate the machining interface. Nevertheless, the persistent use of these fluids presents significant hazards to both human health and the environment. Hence, it is imperative to investigate novel methodologies that can reduce or eradicate the reliance on lubricants. Surface texturing has become a practical method in this situation since it improves the tribological properties of cutting inserts. The main factors that lead to the improvement of tribology are the capture of debris, decreased contact area, and increased lubricating capacity. These factors work together to lower cutting forces, tool deterioration and the surface roughness of the work material. This study provides an extensive analysis of the existing literature regarding the consequences of tool texturing in the process of machining titanium and nickel-based alloys. It scrutinizes techniques that utilize textured tools to enhance machining performance and assesses their influence on several machining parameters. The study explores various techniques for improving performance by analyzing the impact of textured tools on tool wear, thermal profiles, cutting dynamics and surface integrity in different scenarios. These scenarios include dry conditions, high-pressure cooling (HPC), the use of solid lubricants, the application of minimum quantity lubrication (MQL) with and without nanoparticles and the effectiveness of hybrid cryogenic/MQL techniques. This review also provides a comprehensive sustainability analysis, covering both the environmental and economic effects of using textured tools and lubricoolant techniques. Furthermore, this study provides valuable insights for future academic research, identifying areas that are ready for further investigation in this field.