Title: Comparative evaluations of nose wear progression and failure modes during hard turning under dry and near-dry cutting conditions

Authors: Satish Chinchanikar; S.K. Choudhury

Addresses: Department of Mechanical Engineering, Vishwakarma Institute of Information Technology, Pune, Maharashtra, India ' Mechanical Engineering Department, IIT Kanpur, Kanpur, U.P., India

Abstract: In the present work, attempts have been made to compare the tool nose wear progression under dry and near-dry cutting conditions in view of disagreement of the researchers about the use of coolants in hard turning. Hard turning experiments were performed on AISI 4340 steel (55 HRC) using physical vapour deposited (PVD) nanolaminate TiSiN-TiAlN coated carbide tool. Near-dry cutting experiments were performed using a mist formed by a very small quantity of oil (60 ml/hr) and compressed air (5 bar). It has been observed that nose wear progression prominently gets affected with cutting speed in comparison to feed. However, this effect was more prominent under dry cutting conditions. Chipping off at the nose and clearance face was observed as dominant wear forms under both the cutting conditions. No significant difference in tool nose wear progression was observed under both dry and near-dry conditions especially at lower values of cutting speeds (100-125 m/min) and feed (0.081-0.113 mm/rev).

Keywords: tool nose wear; dry cutting; near-dry cutting; hard turning; tool failure modes; ANOVA; dry machining; AISI 4340 steel; PVD nanolaminate; coated carbide tools; cutting speed; feed rate.

DOI: 10.1504/IJMMM.2016.078991

International Journal of Machining and Machinability of Materials, 2016 Vol.18 No.5/6, pp.466 - 482

Received: 20 Apr 2015
Accepted: 29 Dec 2015

Published online: 08 Sep 2016 *

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