Abstract
This study focused on turning AISI P20 and D2 tool steels using coated-carbide cutting tools. In this experimental investigation, an emulsion cutting fluid (CF) aerosol temperature with minimum quantity lubrication (MQL) was varied from 5 °C to 20 °C and its effect on the tool life was evaluated. Trials were done for dry cutting and flood cooling at 25 °C also in same conditions. MQL revealed better tool life for both steels than dry cutting and flood cooling. The tool wear for P20 showed a quadratic behaviour against aerosol temperature, with minimum occurred at 15 °C. At 15 °C, 97% and 93% tool wear reductions were observed from dry cutting and flood cooling respectively. However at 20 °C, tool wear increased by 29% from flood cooling. For D2 steel, similar characteristics were observed with minimum wear at 15 °C. A wear reduction of 96% from dry cutting, and 93% from flood cooling was observed with at 15 °C. MQL at 15 °C leads to a potential means of reducing machining costs. However, trials need to be repeated with different tool material, work-piece material and aerosols to ascertain the generalizability of the findings.
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