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Materials Today: Proceedings 4 (2017) 3627–3635 www.materialstoday.com/proceedings

5th International Conference of Materials Processing and Characterization (ICMPC 2016)

Analysis of Surface Roughness during Machining of Hardened AISI

4340 Steel using Minimum Quantity lubrication
Sanjeev Kumar*, Dilbag Singh, Nirmal S. Kalsi
Department of Mechanical Engineering ,Beant College of Engineering and Technology, Gurdaspur, Punjab - 143521, India

Abstract

Trends of machining hardened steel are increasing in manufacturing industry due to its advantages in surface quality over
grinding and other finishing process. One of the major benefits of hard turning is attaining better surface quality with high
dimensional accuracy. However, large amount of heat generation during hard turning to affects the machining performance. The
application of lubricants during the machining are used to control the temperature. The use of conventional cutting fluids have
become more problematic in terms of health and environmental pollution. Minimization of cutting fluid will lead to cost-
effectiveness in overall machining. Therefore, the aim of this research work is to investigate the role of minimum quantity
lubrication (MQL) technique on surface quality in turning of hardened AISI 4340 steel with CBN tools. The cutting speed, feed
rate, and nose radius and workpiece hardness are selected as process parameters during investigations. The mathematical model
of surface roughness is developed using second order regression analysis. Analysis of Variance (ANOVA) results show that
MQL helps in improving the surface quality as compared to dry and wet conditions in turning.

©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials
Processing and Characterization (ICMPC 2016).

Keywords: CBN, Hard turning, MQL, Nose Radius, Surface roughness;

1. Introduction

Superior surface quality and long life of the finished products are the advantageous features to meet the
challenges of this era in machining processes. Therefore, to achieve this, it is required to optimize the cost, quality and

* Corresponding author. Tel.: +91-75893-44561; fax: +91-1874-221463.

E-mail address:sk_74@rediffmail.com

2214-7853©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).
3628 Sanjeev Kumar et al / Materials Today: Proceedings 4 (2017) 3627–3635

Nomenclature

Ra Surface roughness (µm)

v Cutting Speed (m/min)
f Feed rate(mm/rev)
h Workpiece hardness (HRC)
r Tool nose radius (mm)
DF Degree of freedom

continuous advancement in machining technology that leads to the growth in novel techniques of machining.
Machining of hardened materials is one of them. Hard turned materials are preferred because of their high wear
resistance and better surface quality. In recent years, the hard turning has gained significant attentions in the metal
cutting process as it can apparently replace the traditional process such as grinding and other finishing processes.
When compared to grinding, the hard turning process on nearly net shape parts can lower set-up cost by producing
multiple surfaces in a single set-up. In addition, hard turning requires shorter tool change time, consume low energy
and are environmental-friendly, thereby shows potential cost-effective benefits. Moreover, hard turning has a broad
range of applications in manufacturing industries such as tool and die, automobile, aircraft. The major problem
during hard turning is the high heat generation due to friction between chips-tool interface that cause higher wear
rate, low surface quality and shorter tool lives. Therefore, tool life and surface quality of the components can be
improved by controlling the temperature of cutting zone. Traditionally it is being controlled by using cutting fluids.
The role of cutting fluids used in machining processes is to reduce friction at the tool-workpiece interface and
remove the chip. Procurement, storage and disposals that involve expenses are the main problems associated with
the cutting fluids. In addition, cutting fluids have to obey with environmental legislation such as (Occupational
Safety and Health Administration) OSHA as well [1].
Therefore, in the order to decrease the utilization of cutting fluids without reducing machining
performance, many researchers made attempts to investigate the effects of using minimum quantity lubrication
(MQL) during machining. Varadarajan et al. analysed that machining performance found superior with the use of
minimum amount of cutting fluid when compared to dry and wet conditions. They also observed during MQL, a
major segment of the fluid is evaporated and remaining carried away by the work and chip that cause little
contamination in the surroundings. In addition, temperature decreases significantly at the cutting zone with the use
of MQL when compared with dry and wet conditions [2]. Diniz et al. analysed that the use of compressed air with
the MQL facilitates in getting better surface quality and tool life during machining of SAE 52100 hardened steel
with CBN tool [3]. Khan and Dhar observed a significant drop in temperature at the cutting area with the use of
vegetable oil-based MQL supply during the machining of AISI 1060 steel. The results indicate that due to reduction
in temperature the dimensional accuracy and surface quality are enhanced [4]. Dhar et al. investigated that tool life
and surface quality are improved by the application of MQL during the machining of AISI 4340 steel, when
compared to dry and conventional machining with flooded cooling. The surface finish and dimensional accuracy are
improved mainly due to a reduction of wear [5].
Choudhury et al. observed that the cutting forces are decreased from 5 % to 20% with the use of MQL
supply during the machining. The results shows that axial component of force decreased more than normal
component and surface finish improved due to decrease in tool wear [6]. Kumar and Ramamurthy examined that the
machining performance of cutting tools are superior during MQL supply when compared to dry turning and
traditional wet turning. They also observed during MQL supply the cutting performance depend on parameters such
as nozzle pressure, the number of pulses and the amount of cuttingfluid in each pulse [7]. Tasdelen et al. observed
small contact length between tool–chip with the use of the minimum quantity of liquid along with compressed the
air during the machining. It results better surface quality due to very short engagement times and decrease in friction
in the sliding region [8].
Khan et al. analysed that the significant improvement in tool life and surface quality during machining of
AISI 9310 steel under the application of a minimum quantity of vegetable oil based cutting fluid. They observed that
 Sanjeev Kumar et al/ Materials Today: Proceedings 4 (2017) 3627–3635 3629

with the use of MQL the back surface of chips appears brighter and smoother. It indicates that the reduction in
temperature as results in a decrease in tool wear and surface roughness [9]. Hwang and Lee investigated that the
surface roughness and cutting forces are significantly reduced by the use of MQL supply during the machining of
AISI 1045 steel when compared to the wet condition [10]. Chowdhury and Dhar analysed that surface quality
obtained by the application of MQL is better than dry condition during machining of hardened medium carbon steel.
[11]. Kuarh and Sadaiah analysed that cutting forces are affected by both cutting speed and environmental
conditions during the machining process. The cutting forces are found lesser during MQL supply when compared
with dry and wet environment conditions. The result shows the minimum value surface roughness (Ra) 0.9 µm
during MQL supply whereas 1.2 µm for dry machining and for wet turning 1.1 µm [12]. Lohar and Nanavaty
reported that cutting forces are decreased and surface finish improved with the use of MQL supply during the
machining of hardened steel AISI 4340. They concluded that the cutting temperature is less for 20 ml/min as
compared to 10 ml/min during MQL supply [13]. Hada and Sadeghi reported that cutting performance is improved
by the application of MQL supply during the machining of AISI 4140 steel when compared to dry and flooded
conditions. They also analyzed that position of MQL nozzle as relevant parameters during the machining process [14].
Ekinovic et al. investigated that cutting forces are reduced to 16% by MQL supply during the machining of
aluminium bronze. It is due to a decrease of friction between chip-tool interface. They also observed that MQL helps
in energy saving due to decrease in cutting forces during machining [15]. Da Silva et al. reported that the machining
performance with vegetable-based fluid (Boron, Chlorine and Nitrite free) delivers with MQL provide comparable
performance to that of the dry condition during machining of SAE 1050 steel [16]. Nguyen et al. observed longer
tool life during the hard turning of 9CrSi steel by (MQL) of peanut oil when compared with dry and emulsion MQL
[17]. Naigade et al. observed that surface finish improved by the application of MQL during the machining of
hardened alloy steel AISI 4340 (45 HRC) with CBN insert. In addition, the cutting forces are significantly affected
by depth of cut and cutting environment during the machining [18]. Hadi investigated that optimal surface quality
achieved at cutting fluid supplies 200 ml/h, feed rate 0.08 mm/rev and cutting speed 200 m/min during machining of
AISI H13 steel [19]. Lawal et al. concluded that the surface roughness, tool wear and thrust force are reduced by
application of vegetable based MQL supply during machining of AISI 9310 low alloy steel. In addition, vegetable-
based MQL supply is environmental friendlily and it reduced the cost of machining. The results indicate that the
developed model useful for achieving desired surface roughness close to the tolerance limits by fixing the cutting
parameters during machining [20]. Shihab et al. analyzed the effect of different cutting parameters on cutting force
using Castrol oil as lubricant during hard turning of alloy steel AISI 52100. They developed mathematical models
of cutting force using the response surface methodology (RSM). The results indicate that cutting forces are
influenced maximum by depth of cut [21]. Beatrice et al. developed the model for surface quality based upon
artificial neural network (ANN) when hard turning of AISI H31 steel with MQL [22].
Robinson et al. reported that effect of an auxiliary pulsing jet of water on the top side of the chip in addition
to MQL supply during hard turning of AISI 4340 steel (45 HRC). They noticed the presence of a supplementary
high speed of pulsing jet of water at the tool work boundary improve the chip curl. Also, it reduces tool-chip contact
length and provide better rake face lubrication at the tool-chip interface [23]. Kedare et al. observed the 27%
improvement in surface quality during the use of MQL supply during milling of mild steel (15HRC). The results
also indicate that that MQL supply during machining is an cost-effective and environmental friendly
technique[24]. Dureja et al. observed the optimal value of surface quality at 150 ml/h of cutting fluid supplied with
cutting speed (23 m/min) and feed rate (0.07 mm/rev) while machining AISI 202 steel with coated carbide tools
[25]. Saad et al. analysed longer tool life was observed at 50 ml/h of lubricant supplied during machining of AISI
420 steel (47-48 HRC) [26].
Therefore it is clear from the above mentioned literatures that MQL is an alternative to wet machining.
Although, some studies have been carried out by using MQL supply during hard turning. Also very few studies have
been reported regarding the use of MQL during hard turning of AISI 4340 steel at hardness level below 45 HRC.
Since the hard turning involve machining at hardness levels above 45 HRC. Therefore there is need to study the use
of MQL supply during hard turning of AISI 4340 steel at higher hardness levels i.e. above 45 HRC. Hence, in this
research work perfomance of hard turning using CBN tools will be investigated using MQL at different levels of
hardness and comparison is made with dry and wet conditions during hard turning of AISI 4340 steel.
3630 Sanjeev Kumar et al / Materials Today: Proceedings 4 (2017) 3627–3635

2. Experimental Detail

In this research work, AISI 4340 alloy steel is selected as the workpiece material. It is being used in manufacturing
industries where high tensile and yield strength are required. Components made of AISI 4340 steel are widely used
in aircraft, automotive and general engineering industries e.g. rotor shaft, propeller shafts, connecting rods, gear
shafts, and other automobile parts. The workpiece is heat-treated to obtain high wear resistance. Using standard
methods of heat treatment. The hardened specimens were in five hardness levels at 40, 45, 50, 55, and 60±2 HRC.
After heat treatment, microscopic examinations of the specimens were carried out. The micrographs of specimens at
different hardness level are shown in Fig 1.

Figure 1 Micrograph of heat–treated AISI 4340 steel at 500X.

The micrographs show that fine tempered martensite was observed in the samples 1, 2, 3 and 5 whereas
sample 4 shows the bainitic structure. The goemetry of workpiece material (65 mm diameter and 350 mm length) is
selected as per ISO 3685 standards 1993 [27]. The alloy composition in AISI 4340 steel is given in Table 1. The
inserts grade K5625 having 65% CBN content with ISO geometry SNGA 431S0425MT and tool holder with (ISO)
MSSNR2525M12 of Kennametal are selected for this study.
Table 1 Chemical percentage of element in AISI 4340 steel

Elements % C Mn Si S P Cr Ni Mo Fe
AISI 4340 steel 0.42 0.58 0.27 0.024 0.026 1.06 1.47 0.22 95.93

In this experimental work, four parameters namely cutting speed (v), feed rate (f), nose radius(r) and
workpiece hardness (h). Five levels of each variable are taken. The process variables and their levels are shown in
Table 2.
Table 2 Process variables and their levels

Factors Level-1 Level-2 Level-3 Level-4 Level-5

A: Cutting Speed (v), m/min 75 100 125 150 175

B: Feed Rate (f), mm/rev 0.1 0.125 0.15 0.175 0.2

C: Workpiece hardness (h), HRC 40 45 50 55 60

D: Nose Radius (r), mm 0.2 0.4 0.8 1.2 1.6

 Sanjeev Kumar et al/ Materials Today: Proceedings 4 (2017) 3627–3635 3631

The design of experiment plays a vital role in performing the experiments with the available resources.
Therefore, the central composite design of response surface method was selected to reduce the number of
experiments. This method is useful for developing, analysing, improving and optimizing the products process that
provides an overall perspective of the system response within the design space [28]. According to the central
composite design, 30 experiments were performed. All the experiments were performed at a constant depth of cut of
0.2 mm. The surface roughness (Ra) is chosen as a response variable. A high precision HMT made lathe was used
for experimentation. The schematic diagram for MQL is as shown in Fig 2(a).
Pressure valve

Flow Control Valve

Flow Nozzle
Control
Valve Mixture
Pressure

Compresso
Cutting
oil

(a) (b)

Fig. 2 (a) Experimental set-up for MQL supply (b) Surface Roughness Tester

The surface roughness (Ra) of the AISI 4340 steel was measured with Mitutoyo made surface roughness
tester as shown in Fig 2(b). The average of three measurements was used as a response value. Before the actual test,
the trial run has been performed to get minimum surface roughness against the different rate of cutting fluids supply.
The trial run was carried out at cutting speed 125 m/min, feed rate 0.15 mm/rev, tool nose radius 1.2 mm and at the
hardness of workpiece 45 HRC, 50HRC and 55 HRC. The cutting fluid through the spray gun along with
compressed air at 6 bar. It was found that at 100 ml/hr flow rate, the surface roughness observed to be minimum.

4. Results and Discussion

The analysis of variance (ANOVA) was helpful to study the significance of the process parameters on the
surface roughness. The first order models were not adequate and therefore second order models were generated as
given in Table 3, 4 and 5. The multiple regression coefficient of the model for dry, wet and MQL assisted machining
are estimated as 0.9854, 0.9839 and 0.9859 respectively. The calculated values of F- ratio for the model are greater
than the table values of the F-ratio as shown in ANOVA tables 3, 4 and 5 the model is adequate at 95% confidence
level to represent the relationship between the response and process parameters during hard turning.
Table 3. Analysis of variance for dry turning

Source DF Sum of Mean Fcal p-value Remarks

Square Square Prob ˃ F

Model 13 18.72 1.44 83.12 ˂ 0.0001 Significant

Residual error 16 0.28 0.017 - - -
Lack-of fit 11 0.24 0.022 2.96 0.1207 Non-
Significant
Pure error 5 0.037 0.0073 - - -
Total 29 19 - - -

Rsq = 0.9854 Rsq(adj. ) = 0.9736 Rsq(pred.) = 0.9383

3632 Sanjeev Kumar et al / Materials Today: Proceedings 4 (2017) 3627–3635

The calculated lack-of-fits for the surface roughness models are less than the tabulated value for the lack-
of fit at 95% confidence level. Therefore, it concluded that cutting speed, feed rate, workpiece hardness and tool
nose radius have significant effect on surface roughness Ra, which implies that all model are adequate. The
experimental results were used to compute the mathematical models for each machining conditions. The proposed
second-order models developed from the functional relationship using RSM methods as follows:

Table 4. Analysis of variance for wet turning

Source DF Sum of Mean Fcal p-value Remarks

Square Square Prob ˃ F

Model 14 18.61 1.33 65.45 ˂ 0.0001 Significant

Residual error 15 0.30 0.020 - - -
Lack-of fit 10 0.27 0.027 4.29 0.0608 Non-
Significant
Pure error 5 0.032 0.00636 - - -
Total 29 18.91 - - -

Rsq = 0.9839 Rsq(adj. ) = 0.9689 Rsq(pred.) = 0.9098

Table 5. Analysis of variance for MQL turning

Source DF Sum of Mean Fcal p-value Remarks

Square Square Prob ˃ F

Model 14 16.22 1.16 74.80 ˂ 0.0001 Significant

Residual error 15 0.23 0.015 - - -
Lack-of fit 10 0.21 0.021 3.77 0.079 Non-
Significant
Pure error 5 0.027 0.0054 - - -
Total 29 16.45 - - -

Rsq = 0.9859 Rsq(adj. ) = 0.9727 Rsq(pred.) = 0.9219

Dry hard turning

Ra = + 0.92 – 0.264 *A + 0.161 * B + 0.054 * C - 0.292 * D + 0.354 * A* B – 0.200 * A * C – 0.554 * A * D

– 0.446 * B * D + 0.160 * C * D + 0.164 * A2 + 0.047 * B2 + 0.162 * C2 +0.406 * D2

(i)
Wet hard turning
Ra = +0.67 – 0.43 *A + 0.27 *B + 0.01*C – 0.21*D + 0.12*A*B – 0.31* A*C – 0.38 *A*D + 0.18*B*C
– 0.39*B*D + 0.19*C*D + 0.27*A2 +0.14 *C2+0.30 *D2
(ii)
MQL based hard turning
Ra = + 0.63- 0.40*A+0.27*B+0.098*C-0.22*D+0.12*A*B-0.29*A*C-0.35*A*D +0.17*B*C- 0.37*B*D
+ 0.16*C*D +0.24A2 + 0.11*B2 +0.14 *C2 +0.29*D2
(iii)
The developed mathematical models are used for predicting the relationship between process parameters
and surface roughness as shown in Fig (3 and 4). Fig 3 (a) indicate that that surface roughness decrease with
increase in cutting speed. At cutting speed (75 m/min) the surface roughness observed to be maximum and it start to
decrease with an increase in cutting speed. It is because with increase in cutting speed the friction is reduced that are
accompanied by force decrease lead to a more stable process and better surface quality.
 Sanjeev Kumar et al/ Materials Today: Proceedings 4 (2017) 3627–3635 3633

In addition the with increase in the speed the time for which the chip remains in contact with tool decreases
and the heat is not carried away by the chip. It is one of the primary sources of carrying generated heat. Moreover
when applied lubricant in flooded conditions at coolant may not have enough time to remove heat accumulated at
cutting zone. On the other hand, under MQL the cutting fluid is supplied at high pressure and high velocity that
penetrates into the tool-chip interface that causes reduction in friction and lead to better surface quality. Kumar and
Ramamoorthy [7] have reported a similar study.
The surface quality is also affected by the feed rate. The variation of surface roughness with feed rate is
shown in Fig 3(b) it is observed from the figure that the surface roughness increases with rise in feed rate. It is
beacuse with increase in feed rate large amount of heat generated at the cutting zone due to high material removal
rate. It results in an increase in tool wear which in turn increases the surface roughness.

(a) (b)
Fig 3. Variation of surface roughness with (a) Cutting Speed (b) Feed Rate
In addition when using MQL during the machining, it provides cutting fluids at high velocity with injection
pressure. The high-velocity cutting fluids facilitates better penetration of the cutting fluid on impact to the root as
well as the underside of the chip facilitates its passageway through the tool–chip interface. Which results in the
decrease of friction it leads to decrease in cutting zones temperature and hence surface quality is improved when it
compared with dry and wet machining. Similar analysis has been made by Varadarajan et al.[2].

(a) (b)

Fig 4. Variation of surface roughness with (a) Workpiece hardness (b) Nose radius
3634 Sanjeev Kumar et al / Materials Today: Proceedings 4 (2017) 3627–3635

It has observed from the Fig 4(a) that high surface roughness observed at the starting when workpiece
hardness is 40 HRC. It starts decreasing reaches a minimum values at 55 HRC and then again increases after 55
HRC. As high heat generation due to workpiece leads to plastics deformation which results in a decrease in cutting
forces and hence surface quality improve. However, after 55 HRC the surface roughness increases rapidly, it is due
to the facts that high hardness leads to tool wear in the presence of various hard carbides particles of steel. The same
have been reported by, Derakhshan and Akbari [29] also by Poulachon et al. [30].
Fig 4(b) shows the variations of surface roughness with tool nose radius. It is observed that at tool nose
radius 0.2 mm the surface roughness found to be very high. It is because when machining with small nose radius,
the area of contact available for conduction between the tool and workpiece is small. Hence, the reduction of the
heat conduction area promotes local temperature rise along the cutting edge as results surface roughness increase.
As and when nose radius increases the surface roughness decreases and reaches a critical value and with further
increase in tool nose radius the surface roughness increase. In addition, it observed from the plot that at tool nose
radius 1.6 mm the surface roughness increases. It is because during hard turning with an increase in tool nose radius
the friction between tool and workpiece increases. It leads to the rise of cutting forces and the cutting temperature
the rate of growth of auxiliary flank wear increases as results the surface roughness increases. MQL takes away the
significant portion of heat, reduces the temperature resulting decrease in the dimensional deviation, and improve the
surface quality of the machining.
It have been observed from the above analysis that surface quality found to be superior with the use of
MQL during machining as compared with conventional wet and dry conditions. It is due facts that during MQL
facilitating better lubrication and efficient heat transfer leading to low cutting temperature than flooded cutting
fluids during wet turning.

6. Conclusions

The performance of hard turning is analysed by the surface quality of the machined products. The
performance of MQL during hard turning was investigated and compared with wet turning processes in terms of
surface quality. Based on the above results of the experimental investigations the following conclusions are drawn
for MQL machining
• Surface quality improves by 7 % to 10 % with MQL when compared with flooded supply of lubricants.
Surface finishes developed mainly due to the reduction of wear and damage at the tool tip by the
application of MQL.
• MQL provide advantage primarily by dropping the heat generation at the cutting zone, which leads to
improves tool life and chip-tool interaction. Also, it maintains the sharpness of the cutting edges which
results in better surface quality.
• Surface quality with the use of MQL is better than conventional wet and dry machining. It is due facts that
during regular wet turning, only convective heat transfer extracts the heat, but during MQL, cooling occurs
by convective as well as an evaporative mode of heat transfer occur.

Acknowledgment

The authors are highly thankful to Punjab Technical University, Jalandhar, Punjab, India for continuous technical
support in this field of research works.

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