High-speed turning of AISI 4340 alloy steel using carbide tools in a sustainable minimum quantity lubrication environment

Abstract

Purpose This study aims to investigate the machining performance of CVD-coated carbide tools by considering most crucial machinability aspects: cutting force, tool life, surface roughness and chip morphology in high-speed hard turning of AISI 4340 alloy steel under a sustainable minimum quantity lubrication (MQL) environment. Design/methodology/approach The purpose of this study is to analyze the performance of coated carbide tools under MQL environment therefore, machining tests were performed in accordance with the Taguchi L9 orthogonal array, accommodating the three crucial machining parameters such as cutting speed (V = 300–400 m/min), feed rate (F = 0.1–0.2 mm/rev) and depth of cut (DOC = 0.2–0.4 mm). The measured or calculated values obtained in each experimental run were validated for normality assumptions before drawing any statistical inferences. Taguchi signal-to-noise (S/N) ratio and analysis of variance methodologies were used to examine the effect of machining variables on the performance outcomes. Findings The quantitative analysis revealed that the depth of cut exerted the most significant influence on cutting force, with a contributing rate of 60.72%. Cutting speed was identified as the primary variable affecting the tool life, exhibiting a 47.58% contribution, while feed rate had the most dominating impact on surface roughness, with an overall contributing rate of 89.95%. The lowest cutting force (184.55 N) and the longest tool life (7.10 min) were achieved with low machining parameters at V = 300 m/min, F = 0.1 mm/rev, DOC = 0.2 mm. Conversely, the lowest surface roughness (496 nm) was achieved with high cutting speed, low feed rate and moderate depth of cut at V = 400 m/min, F = 0.1 mm/rev and DOC = 0.3 mm. Moreover, the microscopic examination of the chips revealed a serrated shape formation under all machining conditions. However, the degree of serration increased with an incremental raise with cutting speed and feed rate. Research limitations/implications The study is limited to study the effect of machining parameters within the stated range of cutting speed, feed rate and depth of cut as well as other parameters. Practical implications Practitioners may consider to adopt this machining technique to create more sustainable working environment as well as eliminate the disposal cost of the used metal cutting fluid. Social implications By applying this machining technique, diseases caused by metal cutting fluid to the mechanist will be significantly reduced, therefore creating better lifestyles. Originality/value Hard turning is commonly carried out with advanced cutting tools such as ceramics, cubic boron nitride and polycrystalline cubic boron nitride to attain exceptional surface finish. However, the high cost of these tools necessitates exploration of alternative approaches. Therefore, this study investigates the potential of using cost-effective, multilayer-coated carbide tools under MQL conditions to achieve comparable surface quality. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2024-0013/