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Hard turning of AISI D6 steel with recently developed HSN2-TiAlxN and conventional TiCN coated carbide tools: comparative machinability investigation and sustainability assessment

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Abstract

The alloy steels commonly used for manufacturing of moulds and dies are the metals under hard-to-cut category because of their hardness above 50 HRC in order to attain high performance. In general, ceramic and CBN tools are used for machining hardened steel but its higher cost makes the use for limited applications. However, the usefulness of carbide tool with selective coatings is the best substitute having comparable tool life, and in terms of cost is approximately one-third of ceramic tool while one-tenth of CBN tool. This study addresses the comparative machining performance evaluation and machinability investigation between newly developed second-generation supernitride nanocomposite HSN2-TiAlxN coating with conventional TiCN coated carbide insert in turning of hardened AISI D6 die steel (65 HRC) under dry environment. Several machinability characteristics such as cutting temperature, tool (flank & crater) wear, surface finish, chip morphology, and principal cutting force were analyzed for machining performance evaluation under varying cutting variables (depth of cut, feed, speed). Finally, considering the motivational idea of “Go Green-Think Green-Act Green”, a unique novel approach has been proposed concerning economic evaluation and sustainability assessment in hard turning. Among the tools used, HSN2-TiAlxN coated carbide tool for hard turning application promises, and excellent machinability performances in terms of (i) longer tool life due to lower value of flank & crater wears, (ii) minimum cutting force, (iii) improved surface finish, (iv) lower cutting temperature, and (v) considerable economic advantages as the production cost is reduced by 12%. With the increase in feed, the orientations of all the considered machinability characteristics show an increasing trend. The development of serrated type saw tooth chips was confirmed by chip morphology. In comparison to wet condition, machining in absence of cutting fluid provides an environment friendliness, techno-economical feasible approach to improve sustainability.

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Authors and Affiliations

  1. Department of Mechanical Engineering, DIT University, Dehradun, Uttarakhand, 248001, India

    Anshuman Das

  2. Department of Mechanical Engineering, National Institute of Technology, Rourkela, Odisha, 769008, India

    Madhav Kumar Gupta & Saroj Kumar Patel

  3. Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Odisha, 768018, India

    Sudhansu Ranjan Das, Asutosh Panda & Smita Padhan

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  1. Anshuman Das
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  2. Madhav Kumar Gupta
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  5. Saroj Kumar Patel
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Correspondence to Sudhansu Ranjan Das.

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Das, A., Gupta, M.K., Das, S.R. et al. Hard turning of AISI D6 steel with recently developed HSN2-TiAlxN and conventional TiCN coated carbide tools: comparative machinability investigation and sustainability assessment. J Braz. Soc. Mech. Sci. Eng. 44, 138 (2022). https://doi.org/10.1007/s40430-022-03445-7

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