Assessing near-dry lubrication (35 ml/h) performance in hard turning process of hardened (48 HRC) AISI 1060 carbon steel

Abstract

Turning hardened steel prevailingly initiates intense amount of heat generation and depletion of such extortionate heat from the cutting edge by the application of coolant and/or lubricant induces prolonged tool life and reduces the deterioration of surface quality. However, traditional heat extraction methods fail to satisfy legislation on environmental and health protection, thus hamper sustainability at colossal extent. This study explores and evaluates the propitious role and feasibility of near-dry lubrication (NDL) using soluble oil on the basis of chip tool interface temperature, surface roughness, and chip thickness ratio to compensate the growing demand for ameliorated product quality maintaining “Go Green, think Green and act Green” philosophy. Hard turning of AISI 1060 carbon steel (~ 48 HRC) was performed with the implementation of NDL technique which has been recognized as one of the practical ways to green manufacturing in the context of sustainable production. Herein, responses were also recorded for dry-cut and machining with conventional flood coolant to state a vivid comparison. Furthermore, analysis of variance is employed to analyze the effects possessed by machining parameters on the aforementioned responses and to devise prediction of responses with the aid of formulated mathematical equations. To conclude, NDL provides sufficiently low chip tool interface temperature, improves surface roughness of the machined part, and increases the ratio of chip thickness. Finally, due to significantly less consumption of cutting oils, chances of inhaling nerve-racking gases are foreshortened along with cost related to use and disposal of cutting fluids.