Performance evaluation of coated carbide tool during face milling of AISI 304 under different cutting environments

Abstract

Stainless steel 304 (AISI 304), having wide industrial applications, exhibits poor machinability because of rapid work hardening and poor thermal conductivity. Therefore, cutting fluids are utilized to remove heat and provide lubrication in the machining zone, but their application pose serious environmental and health hazards, calling to minimize their use for green machining. Nano fluid minimum quantity lubrication (NMQL) technique provides an effective alternative to flooded cooling. Current study evaluates performance of NMQL in terms of tool wear and surface finish during face milling of AISI 304 steel. To enhance thermal conductivity of MQL, soluble multi walled carbon nano tubes (1% wt) were mixed in vegetable oil (cutting fluid). Cutting parameters were optimized to minimize tool wear and surface roughness and validation test also conducted under dry, flooded and pure MQL conditions to compare their performance with NMQL machining. Results revealed superiority of NMQL machining over dry, flooded and pure MQL conditions by 7.45%, 2.08% and 5.15% respectively, in terms of tool wear and 54.10%, 34.43% and 39.34 respectively, in terms of surface finish. Wear characterization of tools indicated less adhesion and abrasion marks on tool flank face during NMQL machining compared to dry and flood conditions.