MQL-Assisted Hard Turning of AISI D2 Steel with Corn Oil: Analysis of Surface Roughness, Tool Wear, and Manufacturing Costs

Bogdan Arsene,Flavius Aurelian Sarbu,Gavrila Calefariu,Lucian-Ionel Cioca,Magdalena Barbu,Catalin Gheorghe

doi:10.3390/met11122058

Bogdan Arsene, Flavius Aurelian Sarbu + Show 4 more

Open Access

https://doi.org/10.3390/met11122058

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Abstract

Precision hard turning (HT) gained more and more attention in the cutting industry in the last years due to continuous pressure of the global market for reducing costs, minimizing the environmental and health issues, and achieving a cleaner production. Therefore, dry cutting and minimal quantity lubrication (MQL) became widely used in manufacturing to meet the environmental issues with respect to harmful cutting fluids (CFs). Vegetable oils, in MQL machining, are a promising solutions to petroleum-based CFs; however, the effects and performance on surface roughness and tool wear in HT with ceramic inserts remain unclear. To address this limitation, hardened AIDI D2 steel and pure corn oil, rich in saturated and monounsaturated fatty acids, cheap and widely available, have been used to conduct dry and MQL experiments at different cutting speed and feeds. Results show that corn oil is suitable as cutting lubricant in HT, creating a strong anti-wear and anti-friction lubricating film which improves the roughness with 10–15% and tool life with 15–20%, therefore reducing costs. Best surface roughness values (Ra = 0.151 μm, Rz = 0.887 μm, Rpk = 0.261 μm) were obtained at 180 m/min and 0.1 mm/rev. The analysis of variance shows that corn oil has statistical significance on roughness, validating the results.

Highlights

Nowadays, companies from the modern manufacturing industry face the challenges to reduce costs, increase productivity, and quality of products and minimize the environmental issues, in order to remain competitive in a global and dynamic market [1]
The aim of this paper is to establish the performance of pure corn oil, which represent a novelty in minimal quantity lubrication (MQL)-assisted hard turning with vegetable oil, with respect to surface roughness and tool wear, compared with dry machining, at variable cutting speed and feed, with wiper ceramic inserts commonly used as cheaper alternative to PCBN, in order to meet the conditions of green manufacturing
The performance of commercial available corn oil was investigating with regard to surface roughness and tool wear, on AIDI D2 hardened steel with ceramic wiper inserts

Summary

Introduction

Companies from the modern manufacturing industry face the challenges to reduce costs, increase productivity, and quality of products and minimize the environmental issues, in order to remain competitive in a global and dynamic market [1]. The high quality requirements, the continuously demand for high productivity, the global competition, and the trend toward a cleaner production, push the manufacturers to continuously develop innovative strategies in machining, improve the production processes, take advantage from economic opportunities, and create a greener workplace and eco-friendly machining [2]. To enhance these aspects, the machining process should be as economic as possible, providing a high material removal rate, high quality, reliability, and flexibility. HT became a widely spread cutting technology for both roughing and finishing of revolution parts made by hardened steel with a hardness higher than

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