Experimental Investigation on Cutting Forces in Sustainable Hard Milling of Hardox 500 Steel Under Al<sub>2</sub>O<sub>3</sub>/MoS<sub>2</sub> Hybrid Nanofluid MQCL Environment

Experimental Investigation on Cutting Forces in Sustainable Hard Milling of Hardox 500 Steel Under Al<sub>2</sub>O<sub>3</sub>/MoS<sub>2</sub> Hybrid Nanofluid MQCL Environment

Hardox 500 is a special low-alloy, martensitic steel possessing extraordinary wear resistance, high hardness, and high ductility; thus, it has been widely used in many industrial applications. Nevertheless, this type of steel has a low machinability and is grouped among the difficult-to-machine mate...

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Bibliographic Details
Main Author: Tran The Long
Format: Article
Language:English
Published: MDPI AG 2025-05-01
Series:Lubricants
Subjects:
Hardox 500
hard milling
hard machining
MQL
MQCL
nanofluid
Online Access:https://www.mdpi.com/2075-4442/13/6/240
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Summary:Hardox 500 is a special low-alloy, martensitic steel possessing extraordinary wear resistance, high hardness, and high ductility; thus, it has been widely used in many industrial applications. Nevertheless, this type of steel has a low machinability and is grouped among the difficult-to-machine materials. Hence, this paper’s objective was to study its hard milling performance under minimum quantity cooling lubrication (MQCL) conditions using an Al<sub>2</sub>O<sub>3</sub>/MoS<sub>2</sub> hybrid nano cutting oil. The Box–Behnken response surface methodology was used to investigate the effects of the nanoparticle concentration (<i>NC</i>), cutting speed (<i>v</i>), and feed rate (<i>f</i>) on the total cutting force <i>F</i> and cutting force coefficient <i>F<sub>y</sub></i>/<i>F<sub>z</sub></i>. The obtained results indicate that the cutting efficiency of Hardox 500 steel was improved thanks to the enhancement in cooling lubrication from the MQCL using the Al<sub>2</sub>O<sub>3</sub>/MoS<sub>2</sub> hybrid nano cutting oil. The applicability of vegetable oil and coated carbide inserts is thus extended to the hard milling of difficult-to-cut materials. Moreover, the provision of the appropriate ranges and optimal set of investigated variables obtained in this paper will be useful guides for technologists and further studies. Concretely, <i>NC</i> = 0.5–0.7%, <i>v</i> = 110–115 m/min, and <i>f</i> = 0.08–0.10 mm/tooth are the optimal set for the total cutting force <i>F</i>, while <i>NC</i> = 0.5%, <i>v</i> = 138–140 m/min, and <i>f</i> = 0.08–0.09 mm/tooth are suggested for the cutting force coefficient <i>F<sub>y</sub></i>/<i>F<sub>z</sub></i>.
ISSN:2075-4442

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