Abstract
Minimum quantity lubrication (MQL) is one of the promising green manufacturing technologies to meet the challenges in the dry machining of hardened die steels. The present work aims to show the effects of various machining environments like dry, MQL with compressed air and MQL with oxygen in the milling of H11 die steel. A biodegradable ester LRT 30 (24cSt at 40 °C) was used as a cutting fluid. The results showed that the MQL with an oxygen-enriched environment provided better results in terms of reduction in cutting force, surface roughness and tool wear. It was also found that the MQL with oxygen was more effective when the cutting velocity ranges between 125 and 150 m/min, as compared with conventional MQL with compressed air. The oxygen enriched MQL helps in retaining the tool's sharpness for a longer period due to the formation of hard oxide layer formation on the tool. The cutting tool under MQL with an oxygen environment removes 40% more material when compared to the conventional MQL with air for the same average flank wear width of 0.3 mm.
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