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Machinability investigation of 254 SMO super austenitic stainless steel in end milling under different cutting and lubri-cooling conditions

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Abstract

The application of super austenitic stainless steels (SASS) in the petroleum, chemical, and naval industries has gradually increased owing to their intrinsic properties, such as corrosion resistance and durability. Consequently, the low machinability of SASS is due to its high mechanical strength, low thermal conductivity, and high tendency to work hardening. The understanding of how cutting conditions impact the machining of this material remains limited, highlighting a deficiency in information regarding strategies to enhance its machinability. In this context, the present work analyzes the influence of different cutting and lubri-cooling conditions on machining forces, tool wear, surface roughness, and chip features produced during end milling of SASS 254 SMO. The results showed that depth of cut was the most influential parameter on static and dynamic machining forces, whereas the effect of cutting speed was low expressive. The nanofluid minimum quantity lubrication provided more stability in force values and lower tool failures on the peripheral cutting edge for the total machined length than in flood conditions. In comparison, dry machining resulted in higher tool failure and machining forces. Low roughness values were generated on the sample surface because the end-cutting edge did not exhibit substantial failures. The lubricating effect of NMQL also improves the surface quality of the machined workpiece. On the other hand, dry machining resulted in adhered materials owing to high temperatures in the cutting zone and flood milling in removing material particles from the surface due to work hardening. Furthermore, the generated chips corroborated the analysis of the lubri-cooling effects on the machinability of the material, highlighting the higher temperatures produced during dry cutting owing to changes in the surface color of chips.

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Acknowledgements

The authors thank M.Sc. Abdiel M. Vilanova for the donation of SASS, Liess Co. for the workpiece preparation, Walter Tools Co. for the donation of cutting tools, Bondmann Chemistry for the B90 biofluid, Micromazza Co. for the Way 45-V nanofluid, BR-Sul Microscopy and Microanalysis Center for the SEM images, Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (Grant No. 88887.840963/2023-00) for student scholarship and Federal Institute of Santa Catarina (Process No. 23292.030882/2022-26) for granting leave for study.

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  1. Laboratory of Automation in Machining (LAUS), Mechanical Engineering Department (DEMEC), Federal University of Rio Grande do Sul (UFRGS), Porto Alegre, Brazil

    Émerson S. Passari, André J. Souza & Carlos A. G. Aita

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  1. Émerson S. Passari
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All authors contributed to the study. É.S.P. performed the experimental procedure and wrote the original draft preparation. A.J.S. supervised the study and reviewed/edited the final manuscript. C.A.G.A. helped perform the measurements and data analyses.

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Correspondence to André J. Souza.

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Passari, É.S., Souza, A.J. & Aita, C.A.G. Machinability investigation of 254 SMO super austenitic stainless steel in end milling under different cutting and lubri-cooling conditions. Int J Adv Manuf Technol 131, 6061–6073 (2024). https://doi.org/10.1007/s00170-024-13375-4

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