Effect of cutting speed and feed in turning hardened stainless steel using coated carbide cutting tool under minimum quantity lubrication using castor oil

Abstract

Minimum quantity lubrication is a technique to have the advantages that cutting fluids bring yet keeping their use at minimum. For the cutting fluids, inedible vegetable oils are potential for minimum quantity lubrication machining. Castor oil was selected in this study as the cutting fluid for turning of hardened stainless steel (hardness of 47-48 HRC). The hard turning was with minimum quantity lubrication (50 mL/h flow rate and 5 bar air pressure) at various cutting speeds (100, 135, and 170 m/min) and feeds (0.16, 0.20, and 0.24 mm/rev). The machining responses were tool life, surface roughness, and cutting forces. Design of experiments was applied to quantify the effects of cutting parameters to the machining responses. Empirical models for tool life, surface roughness, and cutting forces were developed within the range of cutting parameters selected. All machining responses are significantly influenced by the cutting speed and feed. Tool life is inversely proportional to cutting speed and feed. Surface roughness is inversely proportional to cutting speed yet is proportional to feed. Cutting forces are more influenced by feed than by cutting speed. A combination of low cutting speed and feed was the optimum cutting parameters to achieve long tool life, low surface roughness, and low cutting forces.

Experimental investigation of surface roughness, flank wear, chip morphology and cost estimation during machining of hardened AISI 4340 steel with coated carbide insert

“…The variable levels of the machining parameters have been selected within the intervals by taking account, the recommendations of manufacturer of the cutting tool (Taegutec Ltd.) and supported by previous work of various authors for investigating surface roughness, tool wear and chip morphology (Lima et al 2005;Dogra et al 2011;Sahoo & Sahoo 2013;Shihab et al 2014;Elmunafi et al 2015;Panda et al 2016). The identified factors and their associated levels are presented in Table 1.…”

An experimental study on the effect of tool geometry on tool wear and surface roughness in hard turning

“…And the quadratic mathematical models have the high determination coefficients R 2 for power consumption, surface roughness, and tool wear. And Elmunafi et al 21 also showed that the trend of influence of cutting condition including cutting speed and feed rate on surface roughness, cutting forces and tool life is similar between dry hard turning and under minimum quantity lubrication using castor oil.…”

Dry Milling Machining: Optimization of Cutting Parameters Affecting Surface Roughness of Aluminum 6061 using the Taguchi Method

“…Sometimes, although surface roughness is undesirable for certain manufacturing products, it is quite difficult to control and may incur higher machining costs (Singh et al, 2020). Elmunafi (2015) has reported that cutting speed is the most significant cutting parameter, followed by feed rate and depth of cut (Elmunafi et al, 2015;Tapadar et al, 2017). On the other hand, Liu (2016) has reported that feed rate is the most significant factor that affects surface roughness, followed by depth of cut and cutting velocity, for minimizing energy consumption (Liu et al, 2016).…”