Several methods are proposed for the machining of Hastelloy-X such as fluid cutting, dry cutting, hot ultrasonic assisted turning (HUAT), laser micro and macro machining and ultrasonic processes. The ultrasonic assisted turning method the material cutting is based on the vibration generated in the material. The amplitude of vibration increases with the increase in frequency and results in cutting of the material. In the conventional process, the reduced cutting forces are applied on the surface to improve the quality of surface and to reduce the residual stresses generated in the material (Liang, Liu, & Wang, 2018). The cutting process of Hastelloy-X requires considerable life extension, cutting tool working ability, cutting speed, critical speed, and the effect of conventional turning operation. The operation gradually becomes conventional for the cutting process mathematical formalism of the work is mentioned below,

V_( cr)  =   2 π fA   … … … … … … ( 1 )

x (t)=  A  sin⁡〖(ω t)〗   +Vt  … … … … … … ( 2 )

x^' (t)=  ω A cos⁡(ω t)   +V  … … … … … … ( 3 )

ω =  2 π f   … … … … … … ( 4 )

The present work deals with the biohazards of cutting fluid method and how it can be replaced by the dry method. The dry cutting has both positive and negative impact on the machining of Hastelloy-X (Sofuoğlu, Çakır, Gürgen, & Orak, 2018). The positive impact dry machining process on the machining of Hastelloy-X is a reduction of environmental hazards. In the present research, the proposed methodology for the dry machining of Hastelloy-X is elaborated and the general approach of the process is also considered (Shyha, Kuo, & Soo, 2014). The research can be divided into two subparts including analysis of dry machining of Hastelloy-X and in the second the part the accuracy and surface integrity is evaluated.

Machining of Hastelloy-X

In the traditional production industry, the machining process is essentially required to improve the quality of the material cutting along with the formation of fine surfaces. There is a number of methods that protect the heating of material and decreases the dimensional sensitiveness of Hastelloy-X. The machining process can be improved by changing the process parameters and the turning operation of Hastelloy-X. The methods developed for the cutting of the material includes fluid cutting, dry cutting, ultrasocial assisted turning, cutting after coating (Sofuoğlu, Çakır, Gürgen, & Orak, 2018). The proper cutting of Hastelloy-X depends on the residual stresses, microcracking, chemical changes in the tool material and the workpiece, tears, changes in the hardness of the surface layer, plastic deformation, and metallurgical transformation (Sofuoğlu, Çakır, Gürgen, & Orak, 2018). The surface integrity changes due to the characterization of machining and milling process. The fluid assisted cutting is hazardous to health, therefore, the dry cutting process can be used to reduce the conventional issues, surface quality, residual stresses, and gradual degradation of the surface. The present work modeled the effect of contamination on health and how it can be controlled (Cestari & Yelverton, 1995).

Surface Integrity of Material 

The research investigated the impact on different parameters on the cutting process and these parameters include the surface integrity of the material after micromachining of Hastelloy-X. The results were predicted by the analysis damage and the temperature of the surface of Hastelloy-X (Sofuoğlu, Çakır, Gürgen, & Orak, 2018). The mathematical model was used to propose the surface roughness after machining. The optimum conditions were selected for cutting the material and to improve the machinability of Hastelloy-X. The numerical investigation worked for the verification of the model for the outputs, morphology of the surface and the chip morphology. The initial temperature of the material was considered as room temperature at 200 C (Sofuoğlu, Çakır, Gürgen, & Orak, 2018). The Cockroft Latham criteria were used for material damage. The shear friction in the modeled material was 0.85 in case of the dry machining of Hastelloy-X.  The model proposes the strain rate modeling and the equation of Johnson Cook model depends on the temperature of the material and the stress generated in the target material (Sofuoğlu, Çakır, Gürgen, & Orak, 2018). The material properties were investigated at different temperature behavior as with increasing the speed of machining the thermal energy of the material increase and consequently the temperature of the material increases. The relation for the surface temperature of the material is mentioned in equation 5 and 6 (Sofuoğlu, Çakır, Gürgen, & Orak, 2018; Skerlos, 2006).

σ =  ( A + B〖 ϵ〗^( n)  )  ( 1 + C ln⁡(( ε)¦(  ε_( 0) )) )  ( 1 -  T^( n) )^m… … … … ( 5 )

T^( n)=  (T  -  T_( m))/(T_( m)   -  T_( n) )… … … … ( 6 )