Internally cooled tools: An eco-friendly approach to wear reduction in AISI 304 stainless steel machining

Abstract

Austenitic stainless steel 304 is widely used in various applications due to its mechanical strength, toughness, and, most importantly, its corrosion resistance. However, machining this material presents significant challenges, primarily due to its high tendency for work hardening and generation of elevated temperatures. In the cutting process, this temperature rise can result in premature tool wear, leading to a reduction in their lifespan. To address these issues, cutting fluids are typically applied. Although this component offers advantages, it also contributes to environmental pollution, health risks, and significant costs, including disposal.Therefore, this study introduces an Internally Cooled Tool (ICT) method aimed at reducing the heat generated during machining. In this study, an analysis of tool life and wear was conducted to evaluate the effectiveness of ICTs compared to conventional machining methods during the turning of austenitic stainless steel 304 using double-coated tools (AlCrN on TiAlN, PVD (Physical Vapor Deposition)). Additionally, the use of ICTs in combination with lubrication (hybrid machining Minimum Quantity Lubrication (MQL) + ICT) was also investigated. The study covered five machining atmospheres (ICT, ICT + MQL, dry, wet, MQL). Cutting conditions were kept constant, including cutting speed (vc = 400 m/min), feed rate (f = 0.1 mm/rev), and depth of cut (ap = 0.5 mm). Scanning electron microscopy (SEM) analyses were conducted to examine the wear mechanisms and types present in each condition, along with statistical tests such as analysis of variance and Tukey tests to validate the experiments. The results indicated that ICTs (ICT and ICT + MQL) showed a longer tool life compared to dry machining and MQL techniques, while the wet machining method did not demonstrate significance compared to this technique. The observed wear mechanisms included abrasion, adhesion, and diffusion, with abrasion being the predominant mechanism. In summary, it was found that the durability of the inserts was directly related to coating adhesion, as coating detachment quickly led to the end of the insert's lifespan.