Executive Summary : | The manufacturing process can have a less impact on the economy and ecology if energy and material utilization are minimized. Nickel and titanium-based alloys are widely used in various industries due to their superior fatigue, corrosion, creep resistance, and strength-to-weight ratio. However, their machining is challenging due to poor heat transfer ability, high chemical reactivity, and work hardening behavior at higher temperatures, resulting in poor machinability. To address these issues, technological innovation is needed to improve machinability. The proposed research explores sustainable cooling/lubrication techniques using hybrid vegetable oil-based nanofluids during machining difficult-to-cut materials using ultrasonic-assisted turning and textured tools. The work proposes the development of a cBN coating on tools through an electrostatic spray process followed by the deposition of TiN-TiAlN coating through chemical vapor deposition (CVD). The valley structures between the developed coating layer will be filled by a layer of Molybdenum disulfide (Mos₂), providing improved heat transfer and lubrication in the cutting zone. The study aims to develop and identify the most suitable machining environment to understand technological, economic, and sustainable aspects such as machining performance, productivity, machining costs, energy consumption, carbon emissions, and impact on health and the environment during machining difficult-to-cut materials. The dissemination of research findings and developed technology to Indian metal-cutting industries will strengthen the Make in India initiative and impart cutting-edge research exposure in hybrid and sustainable manufacturing. |