Abstract
Sustainability is the approach to obtain overall efficiency in manufacturing by achieving economic, ecological and societal benefits. This experimental research presents a concise comparative investigation on machinability characteristics of high-strength grade hardened steel (AISI 4340) through dry and MQL environments for sustainability. Surface characteristics and machinability studies such as white layer, surface topology, chip morphology, surface roughness and tool wear/tool life were investigated under both the environments. Tool life under MQL is 32.3% higher compared to dry condition at cutting speed of 50 m/min, feed rate of 0.08 mm/rev and depth of cut of 0.1 mm, respectively. In another setting of cutting speed of 100 m/min, feed rate of 0.04 mm/rev and depth of cut of 0.1 mm, tool life under MQL condition is 39.6% more than dry condition. Phenomenon like abrasion, diffusion, notching, chip** and built-up edge is reported as principal wear mechanism. Detailed investigation is still needed for sustainable machining using nano-assisted MQL environments.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Rashid WB, Goel S, Davim JP, Joshi SN (2016) Parametric design optimization of hard turning of AISI 4340 steel (69 HRC). Int J Adv Manuf Technol 82(1):451–462
Rashid WB, Goel S, Luo X, Ritchie JM (2013) An experimental investigation for the improvement of attainable surface roughness during hard turning process. Proc IMechE Part B: J Eng Manuf 227(2):338–342
Sen B, Mia M, Krolczyk GM, Mandal UK, Mondal SP (2021) Eco-friendly cutting fluids in minimum quantity lubrication assisted machining: a review on the perception of sustainable manufacturing. Int J Prec Eng Manuf-Green Technol 8(1):249–280
Dhar NR, Kamruzzaman M, Ahmed M (2006) Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel. J Mater Process Technol 172(2):299–304
Sharma V, Pandey PM (2018) Experimental investigations and statistical modeling of surface roughness during ultrasonic-assisted turning with self-lubricating cutting inserts. Proc of the Inst of Mech Eng Part E: J Process Mech Eng 232(6):709–722
Griffiths BJ (1987) Mechanisms of white layer generation with reference to machining and deformation processes. J Tribol 109:525–530
Arfaoui S, Zemzemi F, Tourki Z (2018) A numerical-analytical approach to predict white and dark layer thickness of hard machining. Mat Manuf Process 33(6):661–669
Ramesh A, Melkote SN (2008) Modeling of white layer formation under thermally dominant conditions in orthogonal machining of hardened AISI 52100 steel. Int J Mach Tools Manuf 48:402–414
Spiech GR, Leslie WC (1972) Tempering of steel. Metall Trans 3(5):1043–1054
Lee WG, Su TT (1999) Mechanical properties and microstructural features of AISI 4340 high-strength alloy steel under quenched and tempered conditions. J Mat Process Technol 87:198–206
Suresh R, Basavarajappa S, Gaitonde VN, Samuel GL (2012) Machinability investigations on hardened AISI 4340 steel using coated carbide insert. Int J Ref Metals Hard Mat 33:75–86
Sahoo A, Rout AK, Das D (2015) Response surface and artificial neural network prediction model and optimization for surface roughness in machining Int. J Ind Engg Comput 6(2):229–240
Lima JG, Avila RF, Abrao AM, Faustino M, Davim JP (2005) Hard turning AISI 4340 high strength low alloy steel and AISI D2 cold work steel. J Mat Process Technol 169:388–395
Dhar NR, Kamaruzzaman M, Ahmed M (2006) Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel. J Mat Process Technol 172:299–304
Gaitonde VN, Karnik SR, Davim JP (2008) Selection of optimal MQL and cutting conditions for enhancing machinability in turning of brass. J Mat Process Technol 204:459–464
Davim JP (Ed) In: Surface integrity in machining (Vol. 1848828742). London, Springer
Maranhão C, Davim JP (2012) The role of flow stress and friction coefficient in fem analysis of machining: a review. Rev Adv Mater Sci 30:267–272
Leppert T, Peng RL (2012) Residual stresses in surface layer after dry and MQL turning of AISI 316L steel. Prod Engg 6:367–374
Outeiro JC, Dia AM, Lebrun JL, Astakhov VP (2002) Machining residual stresses in AISI 316L steel and their correlation with the cutting parameters, machining. Sci Technol 6:251–270
Sobiyi J, Sigalas I (2015) Chip formation characterisation and Tem investigation of worn PcBN tool during hard turning. Machining Sci Technol 19:479–498
Konig W, Klinger M, Link R (1990) Machining hard materials with geometrically defined cutting edges—field of applications and limitations. CIRP Annals-Manuf Technol 39:61–64
Acknowledgements
This research has been financially supported by Science and Engineering Research Board (SERB), DST, New Delhi, India (Grant No. SB/S3/MMER/0054/2013), and authors express their sincere thanks and gratitude. This paper is dedicated to the late Mr. Rabin Kumar Das for his contribution in conducting all experiments and various characterizations of cutting tools and workpiece.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2023 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Sahoo, A.K., Kumar, R., Panda, A., Chandra Mishra, P., Mohanty, T. (2023). Toward Machinability Improvement of AISI 4340 Using CVD Multilayer TiN-Coated Carbide Insert Through MQL: A Case Study. In: Nayak, R.K., Pradhan, M.K., Mandal, A., Davim, J.P. (eds) Recent Advances in Materials and Manufacturing Technology. ICAMMT 2022. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-99-2921-4_84
Download citation
DOI: https://doi.org/10.1007/978-981-99-2921-4_84
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-99-2920-7
Online ISBN: 978-981-99-2921-4
eBook Packages: EngineeringEngineering (R0)