Nickel-based superalloys like Waspaloy are commonly employed in aeronautical engineering, but they are still very hard to machine using dry turning. This paper reports an experimental study on the dry turning of Waspaloy using a full factorial (3 3 ) design to assess the influence of cutting speed, feed rate, and depth of cut on cutting forces, chip temperature, surface roughness, and microhardness. The findings indicate that low feed rates and smaller cuts (ap = 0.3–0.6 mm) lead to a substantial reduction in cutting forces and improve surface quality, with surface roughness values as low as Ra ≈ 0.17 μm. Moderate thermomechanical conditions produced a maximum surface microhardness of about 797 HV. Highly accurate regression models ( R 2 > 0.93) were established using ANOVA, and these models can be used as very useful tools for optimizing the process. The results clearly show that acceptable surface integrity can be achieved during dry turning of Waspaloy without the use of coolants, and this provides a sustainable and industry-relevant machining approach.
Esrafili et al. (Mon,) studied this question.