Effect of cutting parameters on tool life during end milling of AISI 4340 under MQL condition

Abstract

Purpose The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid. Design/methodology/approach The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism. Findings Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool Originality/value A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

Machinability characteristics analysis of hard turning operation on AISI 4340 steel using physical vapor deposition multilayer coated carbide cutting tool in the dry environment

“…68 Infrared thermography of cutting temperature during run nos. 5,6,8,12,18,20,23,25, and 27 are shown in Supplemental Figure 7. The cutting temperature rises as the cutting speed increases as in 80-260 m/min.…”

“…Enterprises may develop a solid rapport with society and depart a good business impression on people by making use of these benefits and beneficial consequences. 5 Dry machining is attracting more investigation due to its environmental advantages. The generation of high temperature in the dry cutting condition with hard machining may impair the desired tool qualities, resulting in the production of built-up layers and edges.…”

Parameter optimization of the MQL nozzle by the computational fluid dynamics

“…( 9), D C is the drag coefficient which uses the spherical drag coefficient model [31], as shown in Eq. (10).…”

“…Çamlı, et al [9] focused on the influence of MQL in the machining of steel parts for rail wheels, results showed that the MQL can reduce the surface roughness and tool wear. Ahmad, et al [10] researched the tool life and wear mechanism of milling AISI 4340, and showed that the tool life was increased and tool wear was reduced when machining with MQL. Jiang, et al [11] researched the effect of cutting parameters on average surface roughness in MQL, wet and dry cutting, and found that the surface roughness under MQL cutting condition was the best.…”

Parametric optimization to establish eco-friendly nanofluid minimum quantity lubrication (NMQL) practice for turning superalloy Inconel 718

“…But, in the actual scenario, dry machining is less effective in difficult-to-machine alloys when more tool life and a high surface finish are in demand (Gupta et al , 2022). In these circumstances, machining using the minimum quantity lubrication (MQL) approach has proven to be a practical alternative for traditional (flood) and dry cutting conditions (Vadnere and Kalpande, 2023). In comparison to flooded machining (30,000–60,000 ml/h), MQL technology accurately lubricates the machining zone with a focused, high-velocity jet that uses only 10–100 ml/h of cutting fluid (Dubey and Sharma, 2023).…”