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

Abstract

The machining of nickel-based super alloys is challenging, owing to the generation of high cutting temperatures, as well as difficulty in maintaining dimensional accuracy and minimizing surface roughness, which compels the use of cutting fluids for reducing these issues due to efficient cooling/lubrication strategies. The present work investigates the comparative performance of four cooling/lubrication techniques: dry cutting, wet, minimum quantity lubricant (MQL) and compressed-air modes in turning Nitronic 60 steel using a new-generation SiAlON ceramic inserts. Several machinability parameters were analyzed for performance evaluation. For this purpose, 16 cycles of turning trials were performed based on Taguchi’s L16 orthogonal array experimental design by varying cutting conditions and lubrication modes. MQL exhibits beneficial effects as compared to the other lubrication conditions concerning low cutting force, improved surface finish, decreased cutting temperature, longer tool life, and lower white layer thickness on machined surface. Burr formation on the saw-tooth chip surface, as well as friction, greatly influenced the tool flank wear due to improper cooling and poor lubrication approach in dry, wet, and compressed-air-cooled machining environments in comparison to MQL-machining. From an economical perspective, the tool life in MQL machining improved by 11%, 72%, and 138% in the comparison with flooded, compressed-air, and dry conditions, respectively. The results of the study demonstrate that using the MQL system can help with heat extraction capability, and provide some promising outcomes.

Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

“…Similarly, the Ra of the MQL system was found to be lower in use compared to dry cutting. 14,15,31 In addition, built up edge (BUE) formation is reduced as the coolant lowers the temperature in the cutting zone. Supplementary Figure 4 also shows the BUE formed in the cutting tool under dry CC.…”

“…In addition, the highest cutting forces were obtained in air cooling, while the lowest cutting forces were obtained in the use of MQL. 14 Gupta and Sood 15 performed the effects of dry cutting, coolant and MQL in two different materials, Inconel-800 and Titanium-II. According to the test results, tool wear, cutting forces and Ra increased by increasing f. Lower cutting forces and better surface quality are achieved in MQL cutting.…”

“…In addition, the highest cutting forces were obtained in air cooling, while the lowest cutting forces were obtained in the use of MQL. 14…”

Investigation on the Performance of Coated Carbide Tool during Dry Turning of AISI 4340 Alloy Steel

“…Machinability of any metal is influenced by four-factors: (a) power, accuracy, and rigidity of the machine; (b) material and geometry of the cutting tool; (c) ductility, hardness, microstructure, and (d) production method of work materials [ 10 , 11 , 12 ]. Tool life, cutting forces, and surface finish are prime aspects while the hard turning of materials are important because it influences their wear characteristics, corrosion resistance, fatigue strength, and tribological performance of machined work [ 13 , 14 ]. Bouzid [ 15 ] conducted high-speed machining of AISI 4340 alloy steel employing a commercially coated cutting insert and reported that increments in cutting speed resulted in faster removal of tool coating, which caused an increase in tool wear rate.…”

Microstructure, Mechanical Characteristics, and Wear Performance of Spark Plasma Sintered TiB2–Si3N4 as Affected by B4N Doping

“…Due to its high melting point, ultra-high temperature ceramics (UHTCs) are the best materials to use in hard environments [ 1 , 2 , 3 , 4 , 5 , 6 , 7 ]. TiB 2 is one of the UHTC that has received a lot of attention due to its impressive list of properties, which includes a higher hardness (33 MPa), higher melting point (3225 °C), abrasive resistance, less heat expansion coefficient, and higher Young’s modulus (530 MPa) [ 5 ]. TiB 2 ′s unique properties have made it useful in a variety of contexts, such as a component in armor, cutting tools, and as components that are resistant to corrosion and wear [ 8 ].…”