Optimization of Cutting Parameter in Turning of Super Duplex Stainless Steel -SDSS 2507 with textured tools under MQL conditions

Abstract

Super-duplex stainless steel (SDSS) 2507 is a type of material known for its outstanding mechanical properties and superior corrosion resistance due to its complex microstructure and the presence of various alloying elements. However, due to these characteristics, machining this material can be challenging. To address this issue, manufacturing industries have been exploring innovative ways to use lubricants during machining while considering their environmental impact. Manufacturing industries have been making efforts to move away from using large amounts of lubricants and instead adopt minimum quantity lubrication techniques. Meanwhile, the advantages of using textured surfaces in improving tribological properties have also been recognized. A lot of research has been done to enhance the performance and durability of components by modifying their surface topography. Recently, textured surfaces have also been applied in cutting tools. The use of micro dimples or linear grooves on the rake or flank face of the tool has been shown to reduce cutting forces, friction coefficients, and cutting temperatures. Consequently, this has led to improvements in machining output parameters and increased tool longevity. This study proposes a new sustainable machining approach by combining two techniques: the use of surface textured tools and minimum quantity lubrication (MQL). Two types of cutting tools were used in the experiment: a surface textured tool with circular pit holes, and a hybrid texture tool with a combination of circular pit holes and linear grooves, both under MQL. The experiments are planned based on fractional factorial design and measured cutting forces and tool flank wear were compared with the predicted forces in order to validate the feasibility of the proposed design. The contribution of each process parameter was determined through the analysis of variance (ANOVA) to assess the percentage impact of each parameter. The cumulative effect of both circular and perpendicular textures provides the hybrid texture with superior debris entrapment capability while acting as a chip breaker which reduces the adhesion between the chip and the insert, resulting in better surface finish and wear resistance and hybrid texture tool significantly reduced the tool flank wear and cutting force.