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Experimental investigation of the low-temperature oil-on-water cooling and lubrication in turning the hardened AISI D2 steel

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Abstract

In this paper, the influence of the cutting speed, feed, and the depth of cut on the cutting force, surface roughness, cutting temperature, and tool wear were experimentally investigated under the low-temperature oil-on-water (LTOoW) cooling and lubrication condition in turning the hardened tool steel AISI D2 (60 ± 1HRC) with the PCBN cutting tool. The results showed that the three-component cutting forces are FY > FZ > FX. The influence of the cutting speed on the cutting temperature is slightly more visible compared to the feed and depth of cut. In this experiment, a satisfactory surface roughness value of 0.54 µm can be obtained, gaining the effect of the turning instead of the grinding. The flank wear values of the PCBN tool are 142 µm and 148 µm at the cutting speeds of 55 and 140 m/min, respectively; however, the flank wear abruptly increases to 668 µm at a 495 m/min, which has a very serious impact on the tool life. The abrasive wear is considered to be a predominant wear mechanism on the flank wear of the PCBN tool. The rake face is dominated by crater wear due to the high temperature, high pressure, high stress, and high friction at the chip-tool interface. Compared with dry hard turning (DHT) condition, the lower surface roughness value, lower cutting temperature, and longer tool life can be obtained at LTOoW.

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Abbreviations

\(v\) :

Cutting speed (meter per minute)

\(f\) :

Feed (millimeter per revolution)

a c :

Depth of cut (millimeter)

\({F}_{\mathrm{X}}\) :

Feed cutting force (N)

\({F}_{\mathrm{Y}}\) :

Radial cutting force (N)

\({F}_{\mathrm{Z}}\) :

Main cutting force (N)

\({\kappa }_{\mathrm{r}}\) :

Major cutting-edge angle (degrees)

\({\kappa }_{\mathrm{r}}^{^{\prime}}\) :

End-cutting edge angle (degrees)

\({\gamma }_{0}\) :

Rake angle (degrees)

\(\alpha\) :

Clearance angle (degrees)

\({\gamma }_{0}^{^{\prime}}\) :

Side clearance angle (degrees)

\({\lambda }_{\mathrm{s}}\) :

Inclination angle (degrees)

\({r}_{\upvarepsilon }\) :

Nose radius (millimeter)

\(b\) :

Chamfer width ((millimeter)

\(\beta\) :

Chamfer angle (degrees)

L :

Spiral cutting length

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Acknowledgements

The authors would like to thank the Provincial Key Laboratory for Green Cutting Technology and Application of Gansu Province, and the Key Laboratory for Utility of Environment-Friendly Composite Materials and Biomass at the University of Gansu Province.

Funding

This work was supported by the Natural Science Foundation of Gansu Province in China (Grant No. 20JR5RA376), National Natural Science Foundation of China (Grant No. 51965031), and Industrial Support Projects of Gansu Province University in China (Grant No. 2022CYZC-68).

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Authors and Affiliations

  1. Key Laboratory of Environment-Friendly Composite Materials of the State Ethnic Affairs Commission, Gansu Provincial Biomass Function Composites Engineering Research Center, Key Laboratory for Utility of Environment-Friendly Composite Materials and Biomass in University of Gansu Province, and School of Chemical Engineering, Northwest Minzu University, No.1, ** East Road, Lanzhou, Gansu Province, 730050, People’s Republic of China

    Linhu Tang, Furong Ma, Yanjun Hu, Baodong Li & Yongji Sun

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  1. Jihui Zhang
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  2. Linhu Tang
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All authors contributed to the material preparation, data collection, and experimental study. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jihui Zhang.

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Zhang, J., Tang, L., Ma, F. et al. Experimental investigation of the low-temperature oil-on-water cooling and lubrication in turning the hardened AISI D2 steel. Int J Adv Manuf Technol 125, 1161–1177 (2023). https://doi.org/10.1007/s00170-022-10692-4

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