Feasibility study of the minimum quantity lubrication in high-speed end milling of NAK80 hardened steel by coated carbide tool

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.

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Performance evaluation of coolant concentration when end milling hardened steel using coated carbide tool

10.1063/5.0051486 ◽

2021 ◽

Author(s):

Nurfarahin Zainuddin ◽

Safian Sharif ◽

Mohd Azlan Suhaimi ◽

Amrifan Saladin Mohruni ◽

Muhammad Yanis ◽

...

Keyword(s):

Performance Evaluation ◽

End Milling ◽

Hardened Steel ◽

Carbide Tool ◽

Coated Carbide Tool ◽

Coated Carbide

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A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.576.60 ◽

2012 ◽

Vol 576 ◽

pp. 60-63 ◽

Cited By ~ 7

Author(s):

N.A.H. Jasni ◽

Mohd Amri Lajis

Keyword(s):

Surface Roughness ◽

High Speed ◽

End Milling ◽

Cutting Speed ◽

Hardened Steel ◽

Depth Of Cut ◽

Feed Speed ◽

Radial Depth ◽

Aisi D2 ◽

Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

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Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

Volume 4: Processes ◽

10.1115/msec2018-6505 ◽

2018 ◽

Author(s):

Kai Guo ◽

Bin Yang ◽

Jie Sun ◽

Vinothkumar Sivalingam

Keyword(s):

Tool Wear ◽

Titanium Alloys ◽

Tool Life ◽

End Milling ◽

Cutting Speed ◽

Carbide Tool ◽

Wear Model ◽

Wear Process ◽

Coated Carbide Tool ◽

Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

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