Tool wear analysis in AISI 52100 steel machining with sustainable approach

Abstract

ABSTRACT Manufacturing industries work towards the development of low toxic, eco-friendly, and sustainable alternatives to save the ecosystem from the harmful effects of traditional cutting fluids used for machining from long decades. The utilization of solid lubricants in machining is an advance alternative aimed at regulating the temperature in the machining zone without causing environmental pollution. The present study illustrates the machining performance of AISI 52100 steel employing solid lubricant-assisted machining (SLAM). The study evaluates the machining performance of SLAM with respect to cutting forces, vibration acceleration, tool wear, chip morphology, and surface roughness against dry machining (DM). The experimental findings indicate that utilizing SLAM leads to a notable decrease in cutting forces, ranging between 45% to 60%, a reduction in vibration acceleration by 14% to 29%, a decrease in tool wear by 11% to 17%, and a substantial improvement in surface finish ranging from 47% to 66% compared to DM.