Abstract:
Nowadays, to improve the machinability of a product, different coolants and lubricants are in
use. However, their costs and their adverse effects on human and environment have become
serious concerns. Therefore, it is necessary to look for other solutions, like the application of
minimum quantity lubricant (MQL). In this regard, the present work evaluated the
machinability characteristics during turning AISI 1045 steel under dry, flood, and MQL
environments using coated carbide inserts as a cutting tool. Machining parameters such as
cutting speeds, 80.00 m/min, 100.00 m/min, and 120.00 m/min, feed rates of 0.04 mm/rev, 0.06
mm/rev, and 0.08 mm/rev, and MQL flow rates 50.00, 100.00, 150.00 200.00 ml/min were
employed. Surface roughness, tool wear, and chip morphology were considered as dependent
variables. A Response Surface Methodology (RSM) was employed to design and analyze the
experiment results. The analysis was done through direct comparison, imaging (SEM and
photo), and statistical analysis (using Minitab 19 software). Results indicated that at low
120.00m/min and 0.08mm/rev machining parameters, a better surface was achieved. Higher
tool wear was observed at a cutting speed of 120.00 m/min &80.00 m/min and a feed rate of
0.04 mm/rev during dry machining compared to flood and MQL. The chip morphology studied
also revealed that at 80.00 m/min cutting speed, 0.04 mm/rev feed rate, and 50.00 ml/min flow
rate, the chip thickness was reduced by 20.00% compared to 120.00 m/min cutting speed, 0.08
mm/rev feed rate, and 200.00 ml/min flow rate. Finally, regression-based surface modeling was
developed using Minitab 19 statistical software. The adequacy of the model was statistically
checked using R2
(97.48%) and different plots, and it was found to be acceptable.
