Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

Abstract

The present research addresses the machinability of hardened die steel (AISI D3, 61HRC) in hard turning using multilayer (TiCN/Al2O3/TiN) coated carbide tool under nanofluid based minimum quantity lubrication-cooling condition, where no previous data are available. Power consumption, flank wear, chip morphology and surface integrity (microhardness, residual stress, white layer formation, machined surface morphology, and surface roughness) are considered as technological performance characteristics to evaluate the machinability. Combined approach of central composite design - analysis of variance, response surface methodology and desirability function analysis have been employed respectively for experimental investigation, predictive modelling and multi-response optimization. With a motivational philosophy of “Go Green-Think Green-Act Green”, the work also deals with energy saving carbon footprint analysis and sustainability assessment to recognize the green manufacturing in the context of safer and cleaner production. under environmental-friendly nanofluid assisted minimum quantity lubrication condition. The quantitative analysis revealed that the cutting speed influenced the power consumption during hard machining (75.78%) and flank wear of coated carbide tool (45.67%); feed rate impacted the surface finish of the machined part (68.8%) significantly. Saw tooth shapes of chip produced due to cyclic cracking. Due to low percentage contribution of error (5.32% to Ra, 6.64% to VB, and 7.79% to Pc), a higher correlation coefficient (R2) was obtained with the quadratic regression model, which showed values of 0.9, 0.88 and 0.92 for surface roughness, flank wear, and power consumption, respectively. Optimization with the highest desirability (0.9173) resulted the optimum machining conditions under NFMQL at the cutting speed of 57 m/min, depth of cut 0.1 mm, feed of 0.07 mm/rev, and insert’s nose radius of 0.4 mm. As a result, under NFMQL tool life was improved by 30.8% and 22.6% in respect of flank wear and surface roughness respectively than when machining with MQL technique by adapting the optimum machining condition. Therefore, using hard nanoparticles-reinforced cutting fluid under minimum quantity lubrication condition in practical manufacturing becomes very promising to improve sustainability.

An investigation on cutting sound effect on power consumption and surface roughness in CBN tool-assisted hard turning

“…29 Considering these reports, researchers are giving more emphasis to reduce the electricity consumption in several machining activities. 30…”

“…29 Considering these reports, researchers are giving more emphasis to reduce the electricity consumption in several machining activities. 30 The present research estimated the power consumption in the CBN tool-assisted hard turning. The measured power consumption for L 27 experiments was displayed in Table 1.…”

Investigation on surface roughness, tool wear and cutting power in MQL turning of bio-medical Ti-6Al-4V ELI alloy with sustainability

“…One unit of electricity (≈1 kWh) emits 0.523 kg of CO 2 as per Ministry of Energy in India. 53,54 It is observed that machining under MQL at optimal parametric conditions reduces energy consumption (53.96%) and enhances carbon footprints savings (68.46 kg of CO 2 ) and thus saves in manufacturing cost Thus environmentally conscious MQL machining provides better economical and socio-technological benefits towards green machining and cleaner production for industry as per sustainability concern.…”

Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different Cooling/Lubrication Conditions

“…However, none of these studies explored in a systematic way, which is required for worthwhile research in terms of uniqueness to consider the physical aspect of machining science. From the open literature, it is clear that many investigators have carried out Al 2 O 3 -based ceramic tools during machining to assess their cutting performance [ 31 , 32 , 33 ]. However, the use of newer generation silicon-strengthened.…”