Machining of Austenitic Stainless Steel Under Various Cooling-Lubrication Strategies Smita Padhan, Ajay Kumar Behera, and Sudhansu Ranjan Das Abstract This work highlights the performance analysis of four distinct cooling- lubrication techniques (dry, flood, minimum quantity lubricant MQL and compressed-air) in turning Nitronic 60 by using new generation SiAlON ceramic inserts. Several machinability parameters such as cutting force, cutting temperature, cutting tool wear, surface finish and cost estimation were analyzed for machining performance evaluation. It was observed that machining under MQL condition exhibit beneficial effects as compared to other three pre cited cooling and lubrication condition as the cutting fluid is applied in spray jet form to the cutting zone. Result shows that the tool life in machining under MQL are 138, 72 and 11% greater than dry, compressed air, flooded condition, respectively. The use of SiAlON ceramic tool results in more economically feasible under MQL environment as the total machining cost per component is lower (Rs. 19.79) in comparison to dry (Rs. 26.81), compressed air (Rs. 23.4), flooded (Rs. 21.76) machining conditions. KeywordsMachinability · Cost analysis · Cutting environment · SiAlON ceramic · Nitronic 60 1 Introduction In present day, nickel-based alloys are commonly employed for various industrial applications because of its unique properties like weldability, formability, capability to retain its strength and toughssness at elevated temperature, excellent resistance to creep, thermal and corrosion. Because of its outstanding physical and chemical properties, the use of nickel-based alloy is not only bound to aerospace industry but it S. Padhan · SR. Das ( B ) Department of Production Engineering, Veer Surendra Sai University of Technology, Burla 768018, India e-mail: firstname.lastname@example.org A. K. Behera Department of Mechanical Engineering, Siksha O Anusandhan University, Bhubaneswar 751030, India The Authors, under exclusive license to Springer Nature Singapore Pte Ltd. P. Pradhan et al. (eds, Recent Advances in Mechanical Engineering, Lecture Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-16-9057-0_46 435
S. Padhan et al. also extensively used in nuclear power plant, oil and gas power industries, architecture building and construction, transport, food processing equipment, in various consumer products and medical applications. Despite various advanced methods, machining is still considered to be one of the commonly used processes as the manufacturer can easily achieve the desired structural and the functional features on the component. However, the manufacturing engineer faces big challenges to machine nickel-based alloys as very high temperature and stress are developed during machining resulting work hardening of workpiece which primarily impacts on the tool life and surface quality of machined component. If the selection of cutting parameters and their ranges is not chosen properly with reference to the selected tool and work material combination, then it can lead to the degradation of workpiece quality and failure of the cutting tool by exceeding its tolerance limits. Therefore, to minimize the above pre-cited issues the use of an effective C/L environment is very essential which will be valuable from technological, economic and ecological prospective. The use of cutting fluids in machining process by using different CL strategies remarkably increase the efficiency of the cutting operation by minimizing friction, controlling heat generation at the machining zone, improving chip removal rate and preventing corrosion. The cutting fluids effectively extract heat from machining area by continuously flowing through the cutting zone. It can also provide lubrication effect by forming a thin layer of oil film on cutting interface depending upon adhesive and cohesive nature of cutting fluid. Many researchers have been worked on different CL strategies [ 1 – 4 ] to enhance the cutting performance and machinability [ 7 , 8 ] of different hard-to-cut and difficult-to-cut workpiece materials during turning operation (EN, EN-31,42CrMo4, 17CrNiMo6, Haynes, Ti6Al4V, Inconel 825, 800, 718, AISI 202, AISI 316, AISI 420, AISI 1015, AISI 4140, AISI 4340, AISI 1045, AISI 1060, AISI 52,100, AISI D. Based on considering previous research contribution, the primary purpose of the present study is (i) to evaluate cutting efficiency of modern generation SiAlON ceramic insert, (ii) to explore a comparative investigation toward machinability enhancement by using different cooling lubrication methods (i.e. MQL, flooded, compressed air-cooled, and dry) and (iii) to evaluate the overall machining cost per part during turning under various CL environments.