Abstract
Large quantities of coolant–lubricants are still widely used in the metal working industry, generating high consumption and discard costs and impacting the environment. This paper presents the evaluation of the performances of the various machining environments (dry, conventional wet and MQL technique) applied in hard turning of the AISI 4140 high-strength low alloy steel with coated mixed ceramic (CC6050) in terms of surface roughness, cutting force components, and tool wear. For this purpose, a number of machining experiments based on statistical four-factor (cutting speed, feed rate, depth of cut, and cutting radius) and hybrid-level factorial experiment designs uncompleted with a statistical analysis of variance were performed. The results indicate that the resulting cutting force obtained with the MQL machining process significantly improved when compared with other machining processes. For example: FRMQL ≈ 1.08 FRdry and FRwet ≈ 1.37 FRdry. Then, the RSM was utilized to define the optimal machining parameters. Finally, the ranges for best cutting conditions are proposed for serial industrial production.
Similar content being viewed by others
Abbreviations
- ANOVA:
-
Analysis of variance
- ap (X3):
-
Depth of cut, mm
- BBD:
-
Box-Behnken design
- f (X2):
-
Feed rate, mm/rev
- FR :
-
Resulting cutting force, N
- Fr :
-
Radial force, N
- Ft :
-
Tangential force, N
- HRC:
-
Rockwell hardness
- MQL:
-
Minimum quantity lubrication
- Ra :
-
Arithmetic mean roughness, μm
- Rt :
-
Total roughness, μm
- RSM:
-
Response surface methodology
- r ɛ (X4):
-
Cutting radius, mm
- VB :
-
Flank wear, mm
- Vc (X1):
-
Cutting speed, m/min
- α :
-
Clearance angle, degree
- γ :
-
Rake angle, degree
- λ :
-
Inclination angle, degree
- Χ r :
-
Major cutting edge angle, degree
References
Byers JP (2006) Metal working fluids, second edition. Woodhead, Philadelphia
Nouioua M, Yallese MA, Khettabi R, Belhadi S, Bouhalais ML, Girardin F (2017) Investigation of the performance of the MQL, dry, and wet turning by response surface methodology (RSM) and artificial neural network (ANN). Int J Adv Manuf Technol 93(5–8):2485–2504
Rahim EA, Samsudin ZH, Rahim MAA, Mohid Z (2014) Performance investigation of modified turning tool holder for MQL application. Appl Mech Mater 465–466:1114–1118
Aouici H, Yallese MA, Chaoui K, Mabrouki T, Rigal JF (2012) Analysis of surface roughness and cutting force components in hard turning with CBN tool: prediction model and cutting conditions optimization. Measurement 45:344–353
Bouacha K, Terrab A (2016) Hard turning behavior improvement using NSGA-II and PSO-NN hybrid model. Int J Adv Manuf Technol 86(9–12):3527–3546
Gaitonde VN, Karnik SR, Figueira L, Davim JP (2009) Analysis of machinability during hard turning of cold work tool steel (type: AISI D2). Mater Manuf Process 24(12):1373–1382
Dilbag SP, Venkateswara RA (2007) Surface roughness prediction model for hard turning process. J Adv Manuf Technol 32:1115–1124
Davim JP (2011) Machining of hard materials. (Ed.) Springer
Elbah M, Yallese MA, Aouici H, Mabrouki T, Rigal JF (2013) Comparative assessment of wiper and conventional ceramic tools on surface roughness in hard turning AISI 4140 steel. Measurement 46:3041–3056
Aouici H, Bouchelaghem H, Yallese MA, Elbah M, Fnides B (2014) Machinability investigation in hard turning of AISI D3 cold work steel with ceramic tool using response surface methodology. Int J Adv Manuf 73:1775–1788
Suda S, Yokota H, Inasaki I, Wakabayashi T (2002) A synthetic ester as an optimal cutting fluid for minimal quantity lubrication machining. CIRP Annals - Manuf Technol 51:95–98
Suda S, Wakabayashi T, Inasaki I, Yokota H (2004) Multifuctional application of a synthetic ester to machine tool lubrication based on MQL machining lubricants. CIRP Annals - Manuf Technol 53:61–64
Tasdelen B, Thordenberg H, Olofsson D (2008) An experimental investigation on contact length during MQL machining. J Mat Process Technol 203(1–3):221–231
Shen Bin (2008) Minimum quantity lubrication grinding using Nano fluids. A dissertation submitted in partial fulfillment of the requirements for the degree of doctor of philosophy (Mechanical Engineering) in the University of Michigan
Braga DU, Diniz AE, Miranda GWA, Coppini NL (2002) Using a minimum quantity of lubricant (MQL) and a diamond coated tool in the drilling of aluminum-silicon alloys. J Mater Process Technol 122(1):127–138
Filipovic A, Stephenson DA (2006) Minimum quantity lubrication applications in automotive power-train machining. Mach Sci Technol 10:3–22
Davim JP, Sreejith PS, Silva J (2007) Turning of brasses using minimum quantity of lubricant and flooded lubricant conditions. Mater Manuf Process 22:45–50
Heinemann R, Hinduja S, Barrow G, Petuelli G (2006) Effect of MQL on the tool life of small twist drills in deep-hole drilling. Int J Machine Tools Manuf 46:1–6
Rahman M, Senthil Kumar A, Salam MU (2001) Evaluation of minimal quantities of lubricant in end milling. Int J Adv Manuf Technol 18(4):235–241
Lopez de Lacalle LN, Angulo C, Lamikiz A, Sanchez JA (2006) Experimental and numerical investigation of the effect of spray cutting fluids in high speed milling. J Mater Process Technol 172:11–15
Su YL, Liu TH, Su CT, Yao SH, Kao WH, Cheng KW (2006) Wear of CrC-coated carbide tools in dry machining. J Mater Process Technol 171:108–117
Liao YS, Lin HM (2007) Mechanism of minimum quantity lubrication in highspeed milling of hardened steel. Int J Machine Tools Manuf 47:1660–1666
Wakabayashi T, Sato H, Inasaki I (1998) Turning using extremely small amounts of cutting fluids. JSME Int J 41:143–148
Dhar NR, Ahmed MT, Islam S (2007) An experimental investigation on effect of minimum quantity lubrication in machining AISI 1040 steel. Int J Machine Tools Manuf 47(5):748–753
Kamata Y, Obikawa T (2007) High speed MQL finish-turning of Inconel 718 with different coated tools. J Mater Prorcess Technol 192:281–286
Baheti U, Guo C, Malkin S (1998) Environmentally conscious cooling and lubrication for grinding. Procee Int Seminar Imp Machine Tool Perf 2:643–654
Hafenbraedl D, Malkin S (2000) Environmentally-conscious minimum quantity lubrication (MQL) for internal cylindrical grinding. Trans NAMRI/SME 28:149–154
Silva LR, Bianchi EC, Catai RE, Fusse RY, Franca TV (2005) Study on the behavior of the minimum quantity lubricant - MQL technique under different lubricating and cooling conditions when grinding ABNT 4340 steel. J Brazilian Society of Mech Sci Eng 27(2):192–199
Tawakoli T, Hadad MJ, Sadeghi MH, Daneshi A, Stöckert S, Rasifard A (2009) An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication-MQL grinding. Int J Machine Tools Manuf 49:924–932
Aouici H, Elbah M, Yallese MA, Fnides B, Meddour I, Benlahmidi S (2016) Performance comparison of wiper and conventional ceramic inserts in hard turning of AISI 4140 steel: analysis of machining forces and flank wear. Int J Adv Manuf 87(5–8):2221–2244
Bouchelaghem H, Yallese MA, Mabrouki T, Amirat A, Rigal JF (2010) Experimental investigation and performance analysis of CBN insert in hard turning of cold work tool steel (D3). Mach Sci Technol 14:471–501
Bensouilah H, Aouici H, Meddour I, Yallese MA, Mabrouki T, Girardin F (2016) Performance of coated and uncoated mixed ceramic tools in hard turning process. Measurement 82:1–18
Lima JG, Avila RF, Abrao AM, Faustino M, Davim JP (2005) Hard turning AISI 4340 high strength low alloyed steel and AISI D2 cold work steel. J Mater Process Technol 169:388–395
Yallese MA, Rigal JF, Chaoui K, Boulanouar L (2005) The effects of cutting conditions on mixed ceramic and cubic boron nitride tool wear and on surface roughness during machining of X200Cr12 steel (60HRC). J Eng Manuf Procee IMechE part B 219:35–55
Aouici H, Khellaf A, Smaiah S, Elbah M, Fnides B, Yallese MA (2017) Comparative assessment of coated and uncoated ceramic tools on cutting force components and tool wear in hard turning of AISI H11 steel using Taguchi plan and RMS. Sādhanā 42(12):2157–2170
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Elbah, M., Laouici, H., Benlahmidi, S. et al. Comparative assessment of machining environments (dry, wet and MQL) in hard turning of AISI 4140 steel with CC6050 tools. Int J Adv Manuf Technol 105, 2581–2597 (2019). https://doi.org/10.1007/s00170-019-04403-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-04403-9