Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment
This paper analyzes the surface quality characteristics, such as arithmetic average roughness (Ra), maximum peak-to-valley height (Rt), and average peak-to-valley height (Rz), in hard turning of AISI 52100 steel using a (TiN/TiCN/Al<sub>2</sub>O<sub>3</sub>) coated carbide in...
Saved in:
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-01-01
|
| Series: | Applied Mechanics |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2673-3161/6/1/5 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850205316721934336 |
|---|---|
| author | Sandip Mane Rajkumar Bhimgonda Patil Anindita Roy Pritesh Shah Ravi Sekhar |
| author_facet | Sandip Mane Rajkumar Bhimgonda Patil Anindita Roy Pritesh Shah Ravi Sekhar |
| author_sort | Sandip Mane |
| collection | DOAJ |
| description | This paper analyzes the surface quality characteristics, such as arithmetic average roughness (Ra), maximum peak-to-valley height (Rt), and average peak-to-valley height (Rz), in hard turning of AISI 52100 steel using a (TiN/TiCN/Al<sub>2</sub>O<sub>3</sub>) coated carbide insert under a minimal cutting fluid environment (MCFA). MCFA, a sustainable high-velocity pulsed jet technique, reduces harmful effects on human health and the environment while improving machining performance. Taguchi’s L27 orthogonal array was used to conduct the experiments. The findings showed that surface roughness increases with feed rate, identified as the most influential parameter, while the depth of cut shows a negligible effect. The main effects plot of signal-to-noise (S/N) ratios for the combined response of Ra, Rt, and Rz revealed the optimal cutting conditions: cutting speed of 140 m/min, feed rate of 0.05 mm/rev, and depth of cut of 0.3 mm. Feed rate ranked highest in influence, followed by cutting speed and depth of cut. The lower values of surface roughness parameters were observed in the ranges of Ra ≈ 0.248–0.309 µm, Rt ≈ 2.013–2.186 µm, and Rz ≈ 1.566 µm at a feed rate of 0.05–0.07 mm/rev. MCFA-assisted hard turning reduces surface roughness by 35–40% compared to dry hard turning and 10% to 24% when compared to the MQL technique. Moreover, this study emphasizes the significant environmental benefits of MCFA, as it incorporates minimal eco-friendly cutting fluids that minimize ecological impact while enhancing surface finish. |
| format | Article |
| id | doaj-art-871e2d345d9b46d5b60fdf33f3371fc2 |
| institution | OA Journals |
| issn | 2673-3161 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Mechanics |
| spelling | doaj-art-871e2d345d9b46d5b60fdf33f3371fc22025-08-20T02:11:08ZengMDPI AGApplied Mechanics2673-31612025-01-0161510.3390/applmech6010005Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid EnvironmentSandip Mane0Rajkumar Bhimgonda Patil1Anindita Roy2Pritesh Shah3Ravi Sekhar4Department of Mechanical Engineering, Dwarkadas J. Sanghvi Engineering College, Mumbai 400056, Maharashtra, IndiaDepartment of Mechanical Engineering, Dwarkadas J. Sanghvi Engineering College, Mumbai 400056, Maharashtra, IndiaSymbiosis Institute of Technology, Symbiosis International (Deemed) University, Pune 412115, Maharashtra, IndiaSymbiosis Institute of Technology, Symbiosis International (Deemed) University, Pune 412115, Maharashtra, IndiaSymbiosis Institute of Technology, Symbiosis International (Deemed) University, Pune 412115, Maharashtra, IndiaThis paper analyzes the surface quality characteristics, such as arithmetic average roughness (Ra), maximum peak-to-valley height (Rt), and average peak-to-valley height (Rz), in hard turning of AISI 52100 steel using a (TiN/TiCN/Al<sub>2</sub>O<sub>3</sub>) coated carbide insert under a minimal cutting fluid environment (MCFA). MCFA, a sustainable high-velocity pulsed jet technique, reduces harmful effects on human health and the environment while improving machining performance. Taguchi’s L27 orthogonal array was used to conduct the experiments. The findings showed that surface roughness increases with feed rate, identified as the most influential parameter, while the depth of cut shows a negligible effect. The main effects plot of signal-to-noise (S/N) ratios for the combined response of Ra, Rt, and Rz revealed the optimal cutting conditions: cutting speed of 140 m/min, feed rate of 0.05 mm/rev, and depth of cut of 0.3 mm. Feed rate ranked highest in influence, followed by cutting speed and depth of cut. The lower values of surface roughness parameters were observed in the ranges of Ra ≈ 0.248–0.309 µm, Rt ≈ 2.013–2.186 µm, and Rz ≈ 1.566 µm at a feed rate of 0.05–0.07 mm/rev. MCFA-assisted hard turning reduces surface roughness by 35–40% compared to dry hard turning and 10% to 24% when compared to the MQL technique. Moreover, this study emphasizes the significant environmental benefits of MCFA, as it incorporates minimal eco-friendly cutting fluids that minimize ecological impact while enhancing surface finish.https://www.mdpi.com/2673-3161/6/1/5hard turningminimal quantity lubricationminimal cutting fluid applicationresponse surface methodologysurface roughness |
| spellingShingle | Sandip Mane Rajkumar Bhimgonda Patil Anindita Roy Pritesh Shah Ravi Sekhar Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment Applied Mechanics hard turning minimal quantity lubrication minimal cutting fluid application response surface methodology surface roughness |
| title | Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment |
| title_full | Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment |
| title_fullStr | Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment |
| title_full_unstemmed | Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment |
| title_short | Analysis of the Surface Quality Characteristics in Hard Turning Under a Minimal Cutting Fluid Environment |
| title_sort | analysis of the surface quality characteristics in hard turning under a minimal cutting fluid environment |
| topic | hard turning minimal quantity lubrication minimal cutting fluid application response surface methodology surface roughness |
| url | https://www.mdpi.com/2673-3161/6/1/5 |
| work_keys_str_mv | AT sandipmane analysisofthesurfacequalitycharacteristicsinhardturningunderaminimalcuttingfluidenvironment AT rajkumarbhimgondapatil analysisofthesurfacequalitycharacteristicsinhardturningunderaminimalcuttingfluidenvironment AT aninditaroy analysisofthesurfacequalitycharacteristicsinhardturningunderaminimalcuttingfluidenvironment AT priteshshah analysisofthesurfacequalitycharacteristicsinhardturningunderaminimalcuttingfluidenvironment AT ravisekhar analysisofthesurfacequalitycharacteristicsinhardturningunderaminimalcuttingfluidenvironment |