Machining Performance and Wear Behavior of TiVN-Coated SiAlON Tools in Sustainable Machining of Hardened AISI-D3 Steel under Dry and Hexagonal Boron Nitride-Mixed Nanofluid Minimum Quantity Lubrication Conditions
摘要
Recent advancements in Minimum Quantity Lubrication (MQL) and nanofluid MQL (nMQL) have shown notable success, particularly when using carbide cutting tools. However, there is a scarcity of literature examining the impact of these methods on ceramic cutting tools and their influence on machinability outcomes. Hence, in this study, the interaction between a ceramic cutting tool and nMQL by investigating the turning performance of magnetron sputtered TiVN coated SiAlON ceramic cutting tool under dry and nMQL reinforced by hBN nanoparticles were examined. Initially, nanofluids were prepared with varying nanoparticle concentrations of 0.2, 0.6, 0.8, and 1.2 wt.%. The structural characteristics and morphology of the nanoparticles were examined through x-ray diffraction methods and Field emission scanning electron microscopy (FESEM). The prepared nanofluids were integrated into the minimum quantity lubrication system, and their effects on machinability during the turning of AISI D3 hardened steel were evaluated. The machining outcomes, including tool wear, surface roughness, and cutting temperature were compared across dry, base fluid MQL and nanofluid MQL (nMQl). Compared to dry machining, nMQL reduced tool wear by 56%, improved surface roughness by 47%, and decreased cutting temperature by 38%. Similarly, compared to base fluid MQL, tool wear was reduced by 42%, surface roughness improved by 39%, and cutting temperature decreased by 27%. The nanofluid with a concentration of 0.8 wt.% nanoparticle demonstrated the most favorable machining performance. These findings highlight the potential of nMQL with PC/hBN nanofluids as an effective way to improve tool life and machining efficiency offering the opportunities for more sustainable and high performance machining processes.