The effect of vibration and cutting zonetemperature on surface roughness and tool wear ineco-friendly MQL turning of AISI D2

The

effect

of

vibration

and

cutting

zone

temperature

on

surface

roughness

and

tool

wear

in

eco-friendly

MQL

turning

of

AISI

D2

Onur

Özbek

,

Hamit

Saruhan

DuzceUniversity,Turkey

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r

t

i

c

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e

i

n

f

o

Received20December2019 Accepted6January2020 Availableonline16January2020

Keywords: MQL

Cuttingtemperature

Cuttingtoolvibrationamplitude Surfaceroughness

Toolwear

Sustainablemachining

a

b

s

t

r

a

c

t

Today,developmentsintechnologyhavegainedmomentummorethanever,andtheneed forefficiencyinproductionaswellasintheecologicaldomainhasincreasedsignificantly. Studiesexaminingdrymachiningandcoolantremovalhavebeensupersededbythose pre-sentingnewcoolingandlubricationtechniques.Theeffectsonsurfaceroughnessdirectly relatedtofinalproductqualityarebeinginvestigatedintermsoftoollifeandemployee health.Thishasresultedinmorefrequentuseoftheeco-friendlyminimumquantity lubri-cation(MQL)technique,whichhasnowbecomea majorcompetitortodryandcoolant machining.Inthisstudy,AISID2coldworktoolsteel,amaterialwidelyusedinthemold industry,wasusedastheworkpiece.TestswerecarriedoutunderdryandMQLconditions andthetemperature,cuttingtoolvibrationamplitude,toolwear,surfaceroughnessandtool lifewereevaluated.Theexperimentswerecarriedoutusingtwodifferentcuttingtool coat-ingtypes(CVD-chemicalvapordepositionandPVD-physicalvapordeposition)andthree differentcuttingspeeds(60,90and120m/min)ataconstantcuttingdepth(1mm)andfeed rate(0.09mm/rev).Resultsrevealedthattoolwear,cuttingtemperatureandcuttingtool vibrationamplitudewerelowerby23,25,and45%,respectively,comparedtodrycutting. Becauseoftheseimprovements,thesurfaceroughnessoftheworkpiecewasimprovedby 89%andtoollifewasincreasedbyupto267%.

©2020TheAuthors.PublishedbyElsevierB.V.Thisisanopenaccessarticleunderthe CCBY-NC-NDlicense(http://creativecommons.org/licenses/by-nc-nd/4.0/).

Abbreviations:MQL,Minimumquantitylubrication;CVD,Chemicalvapordepositionand;PVD,Physicalvapordeposition;BUE,Built-up edge;Ra,Arithmeticmeanofsurfaceroughness;Rz,Meanof5recessesand5projectionssurfaceroughness.

∗ _{Correspondingauthor.}

E-mails:onurozbek@duzce.edu.tr(O.Özbek),hamitsaruhan@duzce.edu.tr(H.Saruhan). https://doi.org/10.1016/j.jmrt.2020.01.010

2238-7854/©2020 The Authors. Publishedby Elsevier B.V. This is anopen access articleunder the CC BY-NC-ND license (http:// creativecommons.org/licenses/by-nc-nd/4.0/).

1.

Introduction

Intheearly20thcentury,cuttingfluidusebecamewidespread becausedry processingconditions yieldedvery low perfor-manceinterms ofaccuratedimensions,surfaceroughness andtoollife[1–3].Althoughitimprovesthequalityofthefinal product,theuseofcuttingfluidsisknowntobe uneconom-icalaswell ashazardoustohumanhealth.These negative featureshavebeenexaminedinmanystudies[4–8]. Further-more,aftercompletionofitsservicelife,cuttingfluidmustbe disposedof,anditsdisposalcoststwiceasmuchastheprice ofthecuttingfluid[9].Forthesereasons,bytheendofthe20th century,newcoolingandlubricationmethodswerebeing pro-posedandstudied[10–13].Especiallyinthecontextofgreen manufacturing,theMQLtechniquehasbecomeprominentin recentyearsanditsusageisbecomingwidespread.Amongthe mainfeaturesoftheMQLtechniquearethatitreducesthe cut-tingzonetemperatureandtheamountoflubricationneeded toreducefrictioninthecuttingzone.Theheatgeneratedby thefrictionatthecuttingtool-workpieceinterfaceduringchip removalcauses thetemperaturetorise inthe cuttingzone andthistemperaturereducesthehardnessofthecuttingtool material[14].Manyresearchershavereportedthatwiththis loweredhardness,thecuttingtoolwearsfasterandthatthe changedcutting edgeand form ofthe broken chip due to thiswearadverselyaffectsurfaceroughnessanddimensional accuracy[15,16].Therefore,itisimportanttoavoidveryhigh cuttingtemperatures.Indrilling,millingandturning,30–38% improvementinsurfaceroughness[17,18],17.07–59% reduc-tionincuttingforces[17–19], 6.72–51%reductionincutting temperature/tooltip temperature [17,19–21], and 27.5–409% increaseintoollife[20,22,23]havebeenreportedwithMQL machiningcomparedtodrymachining.

Theapplicationofhardcuttingtoolcoatingswasa turn-ingpointinthedevelopmentofcuttingtools[24].Thesehard coatingsprovideasignificantincreaseinwearresistanceand cuttingtoollife.Theyalsoreducetheeffectsofcutting tem-peraturesandcuttingforcesonthecuttingtools.Today,more than70%oftungstencarbidetoolsarecoated[25,26].Carbide toolsareusuallycoatedusingtwomethods:CVDandPVD.The CVDcoatingsexhibitverygoodadhesiontocarbidetoolsand increasetheirwearresistance.WithPVDcoatings,an addi-tionaltoughnessisprovidedtothecuttingedge,aswellasan increaseinwearresistanceofthetools.Theresistanceofthe carbidetoolsagainstdiffusionandoxidationwearalongwith hothardnesspropertiescanbeincreasedbyTiC,TiN,Al2O3, TiCN,TiAlN,TiZrN,TiB2,anddiamondcoatings[27].TheTiN, whichisgenerallyusedinthetoplayerofhard-coatedtools, preventstheformationofbuilt-upedge(BUE)becauseit pro-videsbetterchipcontrolcomparedtoothercoatingtypesand itprovidesdrylubrication[28].

Thevibrationeffectiveon cuttingtoolshasbeen exam-inedinanumber ofstudies,and canbedivided into three categories: freevibration, forced vibration and self-excited vibration[29]. Free vibration dueto the immediateimpact forcesactingonthecuttingtoolisanunanticipatedtypeof vibrationthatisnotexpectedtooccur inthe normalstock removalprocess.This typeofvibration isignoredin stud-iesbecauseithasashorterandtransienteffectcomparedto

theothertwotypesofvibration.Forcedvibrationisdirectly proportional tothe cuttingforce actingon thecuttingtool at regular intervals. Self-excited vibration resultsfrom the dynamicimbalanceoftheturningprocess.Thefrequencyof theself-excitedvibrationisclosetoorgreaterthanthenatural frequencyofthecuttingtool[30].Theaccurateinterpretation ofthevibrationoccurringinthe cuttingtoolisparticularly importantasitisdirectlyrelatedtosurfaceroughnessand toollife.Severalstudieshavebeenconductedonthefactors andvariablesthatincreasethetoolvibrationamplitudesuch ascuttingspeed,feedrate,cuttingdepth,andcuttingforces [31,32].

Inthisstudy,AISID2coldworktoolsteelwasusedasthe workpiece,alongwithCVD-andPVD-coatedtungstencarbide cuttingtoolsThemainpurposeofthisstudyinvestigatedthe effectsofcuttingtoolvibrationandcuttingzonetemperature duringmachining onthe cuttingtoolcoating type,surface roughness(RaandRz),toolwear,andtoollife.

2.

Material

and

methods

Becauseofitshighcarbonandchromiumcontent,AISID2cold worktoolsteelwithhighstrength,hardness(50HRC)and abra-sionresistancewasusedinthestudy.Fortheturningtests, tailstock holes, 250mm in depth and 100mm indiameter, weredrilledtoreducevibrationintheworkpieces.The chem-icalcomponentsoftheAISID2coldworktoolsteelworkpiece materialaregiveninTable1.

Workpiecessuitable forhard turningwereturnedonan AccuwayJT-150CNClathe.Theexperimentswerecarriedout atthreedifferentcuttingspeeds (60,90,120m/min)witha constantfeedrate(0.09mm/rev)andconstantcuttingdepth (1mm)underdryandMQLprocessingconditions.The exper-imentalsetupisshowninFig.1.ThestudyusedtheCNMG 120408formTiAlN-TiNPVD-coatedandTiCN-Al2O3-TiN CVD-coatedtungstencarbidecuttingtools.

Table1–ChemicalcomponentsofAISID2coldworktool steel.

Element C Si Mn P Cr Mo V

% 1.575 0.32 0.3 0.024 11.7 0.74 0.96

Fig.2– Accelerometersmountedonthetoolholderatthreeaxes(X,YandZ)andvibrationdata.

TheB1-210modelMQLsystemproducedbyBielomatikwas used.Intheexperiments,thelubricantusedwastheca.100% biodegradable,vegetable-basedSAMNOSZM-22Wcuttingoil withadensityof1g/cm3 ₍₂₀◦_{C)and viscosityof1.7mm}2_/s (20◦C). Thisoilwas deliveredtothecuttingzone ataflow rateof150mL/hatadistanceof25mmwitha1-mm diame-ternozzleatapressureof6bar.Thevibrationdatagenerated duringcuttingwere measuredusingtheSpectraQuest soft-wareandhardwaredeviceaccelerometermountedonthetool holderatthethreeaxesofX,YandZ,asshowninFig.2.After thevibrationdatacollectedbytheSpectraQuestsoftwarewere analyzedusingVibraQuest,theaverageofeachaxiswastaken andtheamplitudevaluesoftheX,YandZaxesvibrationof thetoolholderwereplotted.

Thetemperatureatthecuttingzonewasmeasuredusing theOptrisPI450infraredcamera.Theemissivityvalueofthe thermalcamerawastakenas0.81fortheAISID2coldwork toolsteelworkpiecematerial.Thethermalcamerawasfixed totheturretatadistanceof250mmfromthecuttingzoneso thatitmovedwiththecuttingtoolduringcutting.

In order to determine the surface quality of the mate-rial,aftereachexperiment, Ra(arithmeticmean ofsurface roughness)andRz(meanof5recessesand5projections) mea-surementswerecarriedoutfromfivedifferentpointsusinga MahrPS10profilometer.Theamountofflankwearonthe cut-tingtoolswasmeasuredviaaDINOLITE2.0microscope.In ordertobetterunderstandthe weartypesandwear mech-anisms,photographs were taken via aFEIQuanta FEG 250 scanningelectronmicroscope(SEM).

3.

Results

and

discussion

3.1. Cuttingtemperature

Withtheeffectoffrictionduringcutting,ahighamountof heatisproducedinthecuttingzone.Thisheat,uptoacertain

Fig.3–CuttingzonetemperaturesofCVDandPVDcutting tools.

value,facilitatesthecuttingasitallowsforeasyseparation ofthechipfromtheworkpiece.However,theincreasedheat adverselyaffectsthehardnessofthecuttingtool,thus accel-erating the wearofthe tool[14,33]. Fig. 3shows thatMQL reducedthecuttingzonetemperaturebyapproximately100◦C atallcuttingspeedsinbothCVDandPVDcoatedtools.The MQLsystemprovidessomelubricationandreducesfriction onthemachinedsurface[34,35].Thisresultsinalower cut-tingzone temperature.Increasingthecuttingspeed causes thefrictiontoincrease,thusincreasingthecuttingzone tem-perature[36–38].Underall cuttingconditions,lowercutting zonetemperatureswereobservedwithPVDtoolsthanwith CVD-coatedtools.Thisisthoughttobeduetothethermal conductivityoftheAl2O3coatingmaterialinthemiddlelayer oftheCVD-coatedtool.TheAl2O3materialexhibitslow ther-malconductivityathightemperatures.Thismakesitdifficult forthetemperatureatthecuttingtooltiptoexitthecutting

Fig.4–Thermalimagesofchipflowunderdifferentcuttingconditions:a)Dry;b)MQL.

zone[28,39,40].Oneofthereasonsthatthecutting tempera-tureofthecuttingzoneislowduringMQListhatthechipis movedawayfromthecuttingzoneduetothehighpressure oftheMQLsystem.InFig.4,thisisclearlyseeninthethermal imagesofthechipemergingfromthecuttingzoneunderdry andMQLconditions.

3.2. Cuttingtoolvibrations

ShowninFig.5arethevariationsofvibrationamplitude val-uesfortheCVDandPVDtoolsaccordingtothefrequencies measuredatthree axesunderdry and MQLcutting condi-tionsat120m/mincuttingspeed.Theaveragesofthevibration amplitudescollectedatallcuttingspeedsaccordingtotheX, YandZaxesaregiveninFig.6.Thehighestvibration ampli-tudesweremeasuredontheZaxis.Thisarosefromthefact thatmoremovementoccurredintheZaxis,whichwasthe directionofcuttingwherethetoolimpactedtheworkpiece [41].Lowervibrationamplitudevaluesweremeasured with MQLmachiningthanwithdrymachining.Thiswasexplained bythelubricationprovidedbyMQLinthecuttingzonethat reducedfrictionatthecuttingtool-workpieceinterface[34,42], loweredthecuttingzonetemperature[17,19],andreducedtool wear[43].

Thevibrationamplitudevaluesofthecuttingtoolscoated viabothCVDandPVDmethodsroseatallthreeaxeswith increasingcuttingspeed.Thisincreaseisthoughttohavebeen duetothe increaseincuttingtoolwearand the increased centrifugalforce.Increasedtemperatureinthecuttingzone accelerates cutting tool wear. As a result of losses due to wearonthecuttingtooltip,thetipradiusofthecuttingtool andthebrokenchipformdeteriorateasthechipisremoved. Continuousshapeandareachangesoccuratthecutting tool-workpiececontactzone.Wearonthecuttingtoolandsurface roughnessontheworkpieceincreasedbecauseofBUEformed onthecuttingtool.Allthesechangesresultedinchangesin cuttingforces,surfaceroughnessandcuttingtoolvibration values[31].

ThevibrationamplitudevaluesofthePVD-coatedtoolwere lowerthanthoseoftheCVD-coatedtool.Itisthoughtthatthe increasedheatacceleratedthe wearduetotheAl2O3 coat-inginthemiddlelayeroftheCVD-coatedtool,keepingthe temperatureinthecuttingzone,whiletheexcessivevibration

whenremovingthechipwiththeCVD-coatedtoolisthought tohavebeenduetochangesinthecuttingforceonthecutting tool.

3.3. Surfaceroughness

Fig.7showschangesinthesurfaceroughnessdependingon the cuttingspeed of thecutting tools.In the experiments, Ravaluesweremeasuredas0.32–3.26␮mandRzvaluesas 2.22–11.13␮m. The graphs show a significant reduction in bothRaandRzvaluesforbothcuttingtooltypesunderMQL machiningcomparedtodrymachining.ProcessingwithMQL yieldedanimprovementofupto88%inRaand91%inRz com-paredtodryprocessing.Thiswasassociatedwiththelower cuttingzonetemperature,vibrationamplitudevaluesand cut-ting toolwearwith the MQLmachining. Cuttingtoolwear [44–46]andcuttingtoolvibration[47]directlyaffectthesurface roughness.Intheexperiments,thePVD-coatedtools exhib-itedlowersurfaceroughnessvaluesthantheCVD-coatedtools underallcuttingconditions.Thiswasattributedtolesswear onthePVD-coatedtoolsthanontheCVD-coatedtools.There isadirectrelationshipbetweencuttingtoolwearandsurface roughness[44].

Thegraphsshowthattheincreasingcuttingspeedaffected bothsurfaceroughnessvalues(RaandRz).Thiswasattributed totheincreasesinthecuttingspeed,cuttingzone tempera-tureand cuttingtoolwearresultingfrom increasedcutting toolvibrationamplitudes.

3.4. Toolwear

ThegraphinFig.8showsthedifferencesintheCVDandPVD toolsunderdryandMQLconditionsdependingonthecutting speed.Theflankwearinthecuttingtoolswaslowerin exper-imentsperformedwithMQLthanunderdrycutting.Because theMQLsystemprovidessomelubricationinthecuttingzone, itlowersthecuttingzonetemperature,thusreducingwearon the cuttingtool.Theflankwearvaluesofthe cuttingtools increasedwithbothdry and MQLmachiningconditionsas cuttingspeedwasincreased.Cuttingforcesincreaseddueto theincreasedfrictionandcuttingzonetemperatureresulting fromthefastercuttingspeedandconsequently,toolwearwas adverselyaffected[48,49].

Fig.5–VariationofvibrationamplitudevaluesforCVDandPVDcoatedtoolsaccordingtofrequenciesunderdryandMQL cuttingconditionsat120m/mincuttingspeed.

Fig.7–SurfaceroughnesschangesduetocuttingspeedofCVD-andPVD-coatedcuttingtools.

Fig.8–CVDandPVDcoatedtoolsunderdryandMQL conditionsdependingondifferentcuttingspeeds.

ThePVD-coatedtoolwasshowntoperformbetterunder all cuttingconditions than the CVD-coatedtool. The wear resistanceofthecuttingtoolsincreasedwithgreatercoating thickness.However,thiscausesbrittleness,andtheremoval ofthecoating layerbecomesa problem.A thinnercoating provideshighertoughness[50].Generally,CVDcoatingsare thickerthanPVDcoatings.TheCVDcoatingsareata mini-mum6–9␮mthick,whilePVDcoatingsare1–3␮mthick[51]. CoatingsmadeviaPVDaremuchsmootherthanCVDcoatings andcanbedepositedontosharpedges[52,53].

Imagesofthewearonthecuttingtoolstakenbyoptical microscope are shown inFig. 9. Thepictures clearly show that the cutting tools had less wear with MQLmachining andthatthecuttingtoolwearincreasedwithincreasing cut-tingspeed.Ontheotherhand,BUE,causedbytheadhesive wear mechanism, occurred on the cutting tools under all cuttingconditions.TheBUEdimensionsgenerallydecreased withincreasing cuttingspeed. For better understanding of the wearmechanisms, SEM images atdifferent magnifica-tions were taken of the cutting tools for the experiments

carriedoutatafeedrateof0.09mm/revandacuttingspeedof 120m/min(Figs.10–14).TheSEMpicturesshowedthatflank wearandnosewearcausedbytheabrasivewearmechanism had occurredinall cuttingtools.WiththeCVD-coated cut-tingtool,thecoatinglayerhadbeenremovedinsomeareas duringturningunderdrycuttingconditions(Fig.10). Further-more,asaresultoftheremovaloftheTiNcoating(thetop coating),portionsoftheAl2O3coatinglayer(whitepoints)ata depthof40-␮minalineextendingfor400␮mstartingfromthe lowerlimitoftheflankwearcanbeseenontheCVD-coated tool.TheEDSanalysistakenfromthesewhitepointsverifies thissituation,asshowninFig.11.IntheSEMpicturetaken ofthePVD-coatedtoolturnedunderdrycuttingconditions, theflankandnosewear,abrasionmarksandBUEformation areclearlyseenonthecuttingtool(Fig.12).Fig.13showsthe SEMimageoftheCVD-coatedtoolunderMQLmachining con-ditions.Again, flankand nosewearareclearlyseen onthe cuttingtool.Inaddition, theabrasionmarksonthecutting edgeandtheAl2O3 coatingmaterial(themiddlelayer)also standout.However,theresultingBUEformedatthecutting edgeismuchlessthanthatformedunderthedrycutting con-dition.Similarly,theSEMpictureofthePVD-coatedtoolunder MQLmachiningshowstheBUEformationtobemuchlessthan underthedrycuttingcondition(Fig.14).Thus,theMQLsystem greatlyreducedthetypeofBUEthatadverselyaffectssurface roughnessandtoolwear.

3.5. Toollife

Tool wear has a direct impact on surface roughness, pro-duction time, and cost. Since tool life and tool wear are considered as machinability measures, they are important issuesinmachinabilitystudies[54–56].Fig.15showsthetool lifedifferencesbetweentheCVD-coated(Fig.15a)and PVD-coated(Fig.15b)toolsatacuttingspeedof90m/minanda feedrateof0.09mm/revunderdryandMQLmachining con-ditions. MachiningwithMQLprolonged the toollifeofthe CVD-coatedtoolby267%comparedtodrymachining,while thetoollifeofthePVD-coatedtoolwasprolongedby200%. WiththeMQLsystem,theoilreachesthecuttingzoneunder highpressure,reducingthecuttingzonetemperatureand

cut-Fig.9–FlankwearonCVDandPVDcoatedtoolsunderdryandMQLconditionsaccordingtodifferentcuttingspeeds.

Fig.10–SEMimagesofCVD-coatedcuttingtoolunderdrycuttingconditions.

Fig.11–SEMimageofCVD-coatedcuttingtoolunderdrycuttingconditionsandEDSanalysis.

tingtoolvibrationamplitude.Thus,thetoollifewasextended withlong-termprotectionofthecuttingtoolformandreduced toolwear.

With dry machining, the PVD-coated tool life was four timeshigherthantheCVD-coatedtoollife,andthreetimes

higherwithMQL.Thiscanbeexplainedbythehigh temper-atures and vibrationsgeneratedin the cuttingzone ofthe CVD-coatedtool,whichincreasedthewearonthecuttingtool, thusreducingitstoollife.

Fig.12–SEMimagesofPVD-coatedcuttingtoolunderdrycuttingconditions.

Fig.13–SEMimagesofCVD-coatedcuttingtoolunderMQLcuttingconditions.

Fig.15–Toollifedifferencesat0.09mm/revand90m/mincuttingparametersunderdryandMQLmachiningconditions:(a) CVD-coatedtools;(b)PVD-coatedtools.

4.

Conclusion

Inthisstudy,theeffectsofthecuttingzoneoftheMQLsystem oncuttingtemperature,cuttingtoolvibration,surface rough-ness,toolwearandtoollifewereinvestigatedintheturningof AISID2toolsteelwithPVDandCVD-coatedtools.Theresults obtainedfromtheexperimentsaregivenbelow.

Comparedtodrymachining,theeco-friendlyMQLsystem wasfoundtoreducethecuttingzonetemperatureby approxi-mately100◦Catallcuttingspeedsinbothtools(CVDandPVD). Similarly, tool vibration amplitude values decreased with MQLmachining.Comparedtodrymachining,MQLmachining demonstratedsignificantimprovementsinbothRaandRzfor bothcuttingtooltypes.ProcessingwithMQLresultedin88% improvementinRaand91%improvementinRz.Inthe exper-imentscarriedoutwithMQL,lesstoolwearwasseenthan withdrycutting.MachiningwithMQLprolongedthetoollife oftheCVDtoolsby267%andthePVDtoolsby200%compared todrymachining.

ThePVD-coated tools generatedlower cutting tempera-tures than the CVD-coated tools. Moreover, the PVD tool vibration amplitude values were also lower than those of theCVDtools.Thehighestvibrationamplitudeswere mea-sured on the Z axis. In terms of both Ra and Rz values, thePVD-coated toolsshowedbettersurfaceroughness val-uesunderallcuttingconditions.Intoolwear,thePVDtool alsoshowedbetterwear performanceatall cuttingspeeds comparedtotheCVDtool.Under drymachining, the PVD-coatedtoollifewasfourtimeslongerthan theCVD-coated toollife. Under MQLmachining, the PVD-coated toolshad atool lifethree timeslonger than thatof the CVD-coated tools.

Forbothcuttingtooltypes(PVDandCVD)andforboth cut-tingconditions(dryandMQL),withincreasedcuttingspeed, thecuttingzonetemperature,cuttingtoolvibrationamplitude values,surfaceroughness(RaandRz)andtoolwearincreased aswell.

Conflicts

of

interest

There were noconflictsofinterest inthe study.I takefull responsibilityforthis.

Acknowledgments

We would like to thank the Düzce University Scientific Research ProjectsUnit for theircontribution tothe project coded2019.06.05.974and ZirveIndustrialProductsfortheir support.

Appendix

A.

Supplementary

data

Supplementary material related to this article can be found,inthe onlineversion,atdoi:https://doi.org/10.1016/j. jmrt.2020.01.010.

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