Performance of Solid Lubricants and Its Challenges on Textured Tools in Turning

Abstract

Metal cutting is the basis of the manufacturing sector. Cutting fluid is used to dissipate heat produced during metal cutting. Typical cutting fluids have a base of hydrocarbon oil and it contributes to pollution and health problems for the workers. From the results of the experiment solid lubrication is an appropriate option to the cutting fluid that is usually used. Solid lubricants, while initially hard at the site of contact due to frictional heat, eventually smooth out and greatly reduce friction. Few studies have examined alternative textures on cutting tool insert rake surfaces with solid lubricant sustainability. Supplying the cutting area with solid lubricant is crucial, but there is a dearth of research on the topic. This work uses a custom solid lubricant supply system. Turning process is carried out on Inconel 718 in with plain cutting insert in different machining conditions like solid lubricant in paste form and liquid form (solid lubricant mixed with SAE 40 oil in 20:80 ratio) resulted that surface finishing is better during machining with solid lubricant in liquid form. In continuation to that in the present work turning with different textured inserts like parallel, perpendicular and micro hole on the rake face with MoS2, WS2 and CaF2 as solid lubricants in liquid form. Inputs include cutting speed (Vc), feed (f), cutting depth (dcut). The output parameter is surface roughness, flank wear and power consumption. Experiments are executed by utilizing Taguchi L9 OA, and the impact of each parameter on the outcome is assessed using ANOVA approach. The results concluded that WS2 Solid lubricant in liquid form has performed better with all different textured inserts compared to MoS2 and CaF2. When machining with WS2 solid lubricant bended in SAE 40 oil with different textured inserts, micro hole textured inserts has resulted better. Because it is not direction reliant, micro-hole patterning on cutting inserts offers substantial advantages to parallel type and perpendicular type texture. newline newline