Measurement and machinability study under environmentally conscious spray impingement cooling assisted machining

摘要

Environmentally conscious machining evolved as the new concept due to strict environmental regulations and to minimize the hazardous effect on health and environment. Therefore, the present study reports on wear behavior through machinability on hardened AISI D2 steel (55 +/- 1 HRC) using coated carbide cutting insert under cleaner machining approach i.e. spray impingement cooling which is being rarely investigated. Wear at flank surface and roughness of machined workpiece surface are much below of 0.2 mm and 1.6 mm respectively with cutting temperatures lies between 120.4 degrees C and 217 degrees C which shows advantage of compressed air-water spray cooling. Saw tooth shapes of chip produced due to cyclic cracking. At parametric setting of 0.1 mm depth of cut, 0.04 mm/rev feed rate and 108 m/min cutting speed with air pressure 1.5 bar and water pressure of 1 bar, tool life is 105 min with abrasive, chipping and notching are the major form of tool wear. Machined chip volume of 45.36 cm(3) justified as effective and economical hard turning with regression models statistical significant. As a result of the high latent heat absorbed by the water droplets during evaporation through spray impingement cooling, cutting temperature is reduced and thus reduces evolution of tool wear and induced stable and environment friendly cleaner machining. Thus application of spray impingement cooling reduces tool wear, cutting temperature and produced good surface quality that is most acceptable in industrial applications and find itself a new avenue for study on hard turning. (C) 2018 Elsevier Ltd. All rights reserved.