Cryogenic-LN2 and conventional emulsion assisted machining of hardened steel: Comparison from sustainability perspective

Abstract

To achieve an excellent workpiece surface quality and longer tool life in the machining of hardened steel is an excessive challenge. Recently, conventional emulsion cooling assisted machining processes are being used to address this problem. However, such traditional processes have adverse effects on the environment as well as on the machine shop worker’s health. Hence, in this study, the effects of emulsion cooling and sustainable Cryo-LN2 cooling approach on sustainable metrics, such as surface roughness, energy consumption, tool life, and production cost in the external turning of AISI-52100 have been investigated and compared. The comparative results showed that the Cryo-LN2 technique outperformed emulsion cooling for all measured indices. The Cryo-LN2 assisted turning process not only improved surface quality but also consumed 18% less energy consumption and produced 70.9% low-priced products at aggressive cutting parameters as compared to the emulsion. The findings of the current study encourage metal processing industries to use such type of sustainable techniques at a machine shop. This study is based on the “ Think Green, Plan Green and Execute Green” strategy.