Hard turning of AISI D6 tool steel under dry, wet and cryogenic conditions: An economic investigation aimed at achieving a sustainable machining approach

Abstract

The aim of this study was to encourage cleaner production processes by investigating the economic feasibility of using LN2 as a cutting fluid in the turning of quenched and tempered AISI D6 tool steel using solid PCBN inserts. For this purpose, an LN2 supply system was developed to deliver liquid nitrogen to the tool rake and flank faces. In order to measure the LN2 mass flow rate, a system based on load cells was set up. Three different LN2 flow rates (79, 51 and 21 ​L/h) were investigated. For comparison, turning tests under dry and wet conditions using a mineral-based emulsion were also performed. Nose wear (VBC) was monitored and used as one of the input parameters for an economic analysis, which was performed based on a previous study. It was concluded that the LN2 delivery system and the method used for the LN2 flow rate measurement were effective in supplying liquid nitrogen to the cutting zone in a controlled way, and liquid nitrogen at the highest flow rates provided longer cutting tool life than dry and wet conditions. Furthermore, the use of an emulsion did not increase the cutting tool life in comparison with the dry condition and machining assisted by LN2 at the lowest flow rate presented no statistical difference as compared to the wet condition in terms of production cost. Thus, based on this case study, liquid nitrogen can be considered as a sustainable alternative to the use of mineral-based emulsions, without incurring economic losses.