Turning of AISI 9260 using MAC nano coolant: multi‑objective optimization and modeling of cutting parameters using MOGA-RSM

The purpose of this research is to investigate the ease of machining of AISI 9260 steel, mainly focusing on the quality of the surface roughness (SR), flank wear (FW), material removal rate (MRR), and tool life (TL). An alternative to conventional coolant, a nanocoolant is used to overcome the harmful and toxic effects in the turning process. Is a mixture of biodegradable cooking oil and nanoparticles. The weight percentages of nano-Mg particles mixed with palm oil to prepare the nano coolant and is used as the minimum amount of coolant (MAC). The experimental tests are planned according to the RSM-BBD approach. A separate TNMG120404/08 copper-coated carbide insert is used for all tests in the study. The main key factors are feed rate (FR), speed (S), depth of cut (DOC) with three levels along with two categorical factors, nose radius of the tool, and hardness of the material with two levels. The main vital factors are analyzed by response surface method (RSM), desirability function analysis (DFA), and multi objective genetic algorithm (MOGA). The pareto analysis of responses is studied by a MOGA. The mathematical models developed by RSM for both categorical factors are used for simultaneous optimization by MOGA. In the machining test, the nano coolant effects can be observed in reduced flank wear (Vb max) varied from 0.0658 mm to 0.7194 mm, and average roughness varied from 1.42 µm to 12.57 µm. The MOGA's Pareto front exhibits a 0.4 mm nose radius and 45 HRC as the best combination to obtain the required results.