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<p>The present study explores the power consumption and flank wear in hard turning of AISI H13 steel (51 HRC) using AlTiSiN coated carbide tool under multi-walled carbon nanotube (MWCNT) based nanofluid with minimum quantity lubrication (MQL) environment, where no previous data are available. Experiments involving thirty trials were carried out considering several machining variables, namely feed, depth of cut, nose radius and cutting speed. Experimental investigations, prediction modelling and multiple response optimization have all made use of the combined approach of Box-Behnken design—analysis of variance, response surface method and desirability function analysis in an effort to minimize power consumption and flank wear. Finally, in the perspective of safer and cleaner manufacturing under nanofluid-MQL environment, a unique approach termed life cycle analysis (LCA) has been suggested for sustainability assessment in hard turning. According to the results, the most important factor influencing power consumption and tool wear was the cutting speed. The serrated edge saw-toothed chip formation during hard turning led to increased flank wear, which was likely the cause of the higher machining power consumption. The combination of ultra-hard AlTiSiN coated tool and effective nanofluid-MQL cooling-lubrication resulted in lower range of flank wear (0.137–0.293 mm) during hard turning. The desirability function approach presented optimum values of 0.887 kW and 0.137 mm respectively, for power consumption and flank wear at cutting condition: feed of 0.07 mm/rev, speed of 55 m/min, tip radius of 0.4 mm and doc of 0.2 mm under nanofluid-MQL. The findings of the environmental sustainability evaluation using LCA-based data on machining power consumption under ES2013, EF3.0 and CML-IA baseline 2001 indicate that the best machining combinations were achieved with a high speed of 135 m/min, a feed rate of 0.17 mm/rev, a low depth of cut of 0.2 mm and nose radius of 1.2 mm, demonstrating superior environmental performance in multiple impact categories.</p>

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Hard turning of AISI H13 steel with AlTiSiN coated carbide tool using MWCNT based nanofluid under minimum quantity lubrication: experimental investigation and sustainability assessment

  • 期刊论文

  • 发表日期：

    2025年8月20日

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  • Sitesh Mahapatra,
  • Anshuman Das,
  • Soumikh Roy,
  • Pankaj Charan Jena,
  • M. Naresh Babu,
  • Sudhansu Ranjan Das

摘要

The present study explores the power consumption and flank wear in hard turning of AISI H13 steel (51 HRC) using AlTiSiN coated carbide tool under multi-walled carbon nanotube (MWCNT) based nanofluid with minimum quantity lubrication (MQL) environment, where no previous data are available. Experiments involving thirty trials were carried out considering several machining variables, namely feed, depth of cut, nose radius and cutting speed. Experimental investigations, prediction modelling and multiple response optimization have all made use of the combined approach of Box-Behnken design—analysis of variance, response surface method and desirability function analysis in an effort to minimize power consumption and flank wear. Finally, in the perspective of safer and cleaner manufacturing under nanofluid-MQL environment, a unique approach termed life cycle analysis (LCA) has been suggested for sustainability assessment in hard turning. According to the results, the most important factor influencing power consumption and tool wear was the cutting speed. The serrated edge saw-toothed chip formation during hard turning led to increased flank wear, which was likely the cause of the higher machining power consumption. The combination of ultra-hard AlTiSiN coated tool and effective nanofluid-MQL cooling-lubrication resulted in lower range of flank wear (0.137–0.293 mm) during hard turning. The desirability function approach presented optimum values of 0.887 kW and 0.137 mm respectively, for power consumption and flank wear at cutting condition: feed of 0.07 mm/rev, speed of 55 m/min, tip radius of 0.4 mm and doc of 0.2 mm under nanofluid-MQL. The findings of the environmental sustainability evaluation using LCA-based data on machining power consumption under ES2013, EF3.0 and CML-IA baseline 2001 indicate that the best machining combinations were achieved with a high speed of 135 m/min, a feed rate of 0.17 mm/rev, a low depth of cut of 0.2 mm and nose radius of 1.2 mm, demonstrating superior environmental performance in multiple impact categories.