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<p>MgO nanofluid exhibits excellent thermo-physical characteristics and has been effectively applied in heat exchanger research. Using MgO-based nano-cutting fluid as a coolant in machining hardened steel introduces a unique feature, as this cutting fluid has yet to be explored in machining research. In this study, MgO nano-cutting fluid was used for turning hardened AISI D2 steel (57 ± 1 HRC) with a dual jet nozzle MQL system and a CVD-coated (TiCN/Al<sub>2</sub>O<sub>3</sub>) carbide tool. Three distinct weight-based concentrations of nanofluid (0.5, 1, and 1.5% of total weight) were developed and employed as input variables. The cutting temperature was significantly reduced (46.9 to 96.3&#xa0;°C) using MgO nano-cutting fluid, leading to a notable reduction in surface roughness, flank wear, and power consumption. Cutting speed had the greatest effect on tool flank wear (57.36%), cutting temperature (80.60%), and power consumption (63.64%). Furthermore, tool life, carbon emissions, and circularity error were evaluated under optimal cutting circumstances. The tool life based on flank wear criteria (<i>VBc</i> = 0.2&#xa0;mm) and surface roughness criteria (<i>Ra</i> = 0.8&#xa0;µm) was 98 and 90 min, respectively. The comparatively longer tool life of the coated carbide tool ensures improved productivity in the hard turning process.</p>

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A Novel Application of MgO Nano-cutting Fluid in Hardened AISI D2 Steel Machining Using a Chemical Vapor Deposition-Coated Carbide Tool

  • 期刊论文

  • 发表日期：

    2025年1月23日

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  • Rajashree Mallick,
  • Ramanuj Kumar,
  • Amlana Panda,
  • Ashok Kumar Sahoo

摘要

MgO nanofluid exhibits excellent thermo-physical characteristics and has been effectively applied in heat exchanger research. Using MgO-based nano-cutting fluid as a coolant in machining hardened steel introduces a unique feature, as this cutting fluid has yet to be explored in machining research. In this study, MgO nano-cutting fluid was used for turning hardened AISI D2 steel (57 ± 1 HRC) with a dual jet nozzle MQL system and a CVD-coated (TiCN/Al2O3) carbide tool. Three distinct weight-based concentrations of nanofluid (0.5, 1, and 1.5% of total weight) were developed and employed as input variables. The cutting temperature was significantly reduced (46.9 to 96.3 °C) using MgO nano-cutting fluid, leading to a notable reduction in surface roughness, flank wear, and power consumption. Cutting speed had the greatest effect on tool flank wear (57.36%), cutting temperature (80.60%), and power consumption (63.64%). Furthermore, tool life, carbon emissions, and circularity error were evaluated under optimal cutting circumstances. The tool life based on flank wear criteria (VBc = 0.2 mm) and surface roughness criteria (Ra = 0.8 µm) was 98 and 90 min, respectively. The comparatively longer tool life of the coated carbide tool ensures improved productivity in the hard turning process.