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<p>The research addresses the comparative performance between conventional plain tool and textured tool in turning of AISI 6150 spring steel under minimum quantity lubrication (MQL), <i>which has not been addressed before</i>. Nanocomposite AlTiSiN-coated carbide tool was considered as cutting tool material for machinability evaluation focusing on tool life, tool wear (both flank and crater wears), cutting temperature, machined surface morphology, and chip morphology. Based on the estimated tool life in turning, a cost analysis was carried out using Gilbert’s machining economic approach to assess the economic feasibility of the coated tools. It was noticed that insert with a micro-channel pattern type textured offers higher machinability compared to plain one confirming: (a) reduced flank and crater wear, (b) prolonged tool life, (c) superior surface finish, (d) lower cutting temperature with minimized vibration of tool insert, and (e) significant economic advantage as production costs was decreased by around 9%. This behavior is pertaining to the reduced tool–chip interface contact and friction, enhanced lubrication retention capacity, better heat dissipation ability, superior chip breakability, reduction of built-up-edge formation, and improved machining stability with smoother chip flow, which indicates the potential benefits of surface texturing as an efficient tribological improvement for turning operations. Thermographic analysis illustrates that in terms of chip formation; there is a distinct advantage of using textured tools over non-textured tools. Textured tools yielded smooth, uniform chip formation with lower interface temperatures. Non-textured tools yielded uneven serrated chips, hot thermal spots, and strong adhesion.</p>

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Comparative Performance Evaluation Between Conventional Tool and Textured Tool in Turning of AISI 6150 Steel under Minimum Quantity Lubrication

  • 期刊论文

  • 发表日期：

    2026年4月2日

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  • Sarita Mishra,
  • Santosh Kumar Sahu,
  • Sudhansu Ranjan Das

摘要

The research addresses the comparative performance between conventional plain tool and textured tool in turning of AISI 6150 spring steel under minimum quantity lubrication (MQL), which has not been addressed before. Nanocomposite AlTiSiN-coated carbide tool was considered as cutting tool material for machinability evaluation focusing on tool life, tool wear (both flank and crater wears), cutting temperature, machined surface morphology, and chip morphology. Based on the estimated tool life in turning, a cost analysis was carried out using Gilbert’s machining economic approach to assess the economic feasibility of the coated tools. It was noticed that insert with a micro-channel pattern type textured offers higher machinability compared to plain one confirming: (a) reduced flank and crater wear, (b) prolonged tool life, (c) superior surface finish, (d) lower cutting temperature with minimized vibration of tool insert, and (e) significant economic advantage as production costs was decreased by around 9%. This behavior is pertaining to the reduced tool–chip interface contact and friction, enhanced lubrication retention capacity, better heat dissipation ability, superior chip breakability, reduction of built-up-edge formation, and improved machining stability with smoother chip flow, which indicates the potential benefits of surface texturing as an efficient tribological improvement for turning operations. Thermographic analysis illustrates that in terms of chip formation; there is a distinct advantage of using textured tools over non-textured tools. Textured tools yielded smooth, uniform chip formation with lower interface temperatures. Non-textured tools yielded uneven serrated chips, hot thermal spots, and strong adhesion.