Abstract
Inconel 625 is a nickel-based superalloy widely applied in aerospace and energy sectors due to its high strength and corrosion resistance. However, its poor machinability remains a significant challenge in precision manufacturing. This study investigates the influence of tool geometry and cutting parameters on surface roughness of Inconel 625 during turning operations under the minimum quantity lubrication (MQL) conditions. Experiments were carried out using three types of cutting inserts with distinct chip breaker geometries while systematically varying the cutting speed, feed rate, and depth of cut. The results were statistically analyzed using analysis of variance (ANOVA) to determine the significance of individual factors. The findings reveal that both the type of cutting insert and the process parameters have a considerable effect on surface roughness, which is the key output examined in this study. Cutting forces and chip type were examined to provide complementary insights and improve understanding of the observed relationships. Based on the results, an optimal set of cutting data was proposed to achieve a required surface roughness during the turning of Inconel 625 with MQL. Furthermore, a practical algorithm was developed to support the selection of cutting parameters in industrial applications. Analysis of the results showed that a cutting insert with a 0.4 mm corner radius achieved the required surface finish (Rz ≤ 0.4 µm). Furthermore, the analysis revealed a significant effect of the thermal properties of Inconel 625 on machining results and chip geometry.