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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

Performance of TiAlN PVD coated carbide tool in machining

AISI 4340 with Minimum Quantity Lubrication (MQL)
condition
Mahros Darsin*, Rika Dwi Hidayatul Qoryah, Robertus Sidartawan, Allen
Luviandy, Aris Zainul Muttaqin, Dwi Djumhariyanto
Mechanical Engineering Department, University of Jember
Kalimantan 37 Jember 68121, Jawa Timur, Indonesia
*Email: mahros.teknik@unej.ac.id

Abstract. There are several ways to assess machinability, viz. forces that are working during
machining, the surface roughness of machined part, chip formation, and tool performance. This
article aims to observe the machinability from the tool performance perspective when machining
with minimum quantity lubrication (MQL). The MQL device can either be time-controlled or
temperature-controlled using an Arduino. The machining was carried out on a conventional lathe
toward a bar of AISI 4330 using carbide coated insert tools. The experiments were carried out using
Taguchi design L9, by the varying depth of cut, coolant composition and method of applying the
coolant. Tool performance was evaluated by tool deterioration value. There are four levels of tool
deterioration according to its severities after machining. Analysis of variance shows that depth of
cut more influence to the tool performance than the coolant application method by 32.69% and
12.82% each, respectively. However, it is proof that MQL with temperature-controlled would
contribute to the minimum tool deterioration.

Keywords: carbide coated, insert tool, machinability, MQL, Taguchi

1. Introduction
Applying cutting fluid is very common in machining. It will smoother the machined surface [1],
cooling the interface of tool-chip during machining [2] and consequently will make tool life longer
[3] than machining without it. However, using the cutting fluid give adverse effect to the
environment because of its material is from petroleum-based, which is not degradable. Some of
the cutting fluid can evaporate to be fume due to heat generated during machining, which may
damage the operator. Some efforts have been carried out by different researchers to overcome
these disadvantages. One of those efforts is trying to use bio-based cutting fluids material which is
degradable such as palm oil, castor oil, vegetable oil, etc. [4-6]. Another effort is by reducing the
use of cutting fluid which is known as minimum quantity lubrication (MQL). Some previous
research revealed that machining with MQL could improve the surface quality of the machined
part [7-8] and prolonged the tool life [7,9] in advanced of being able to reduce the cost of cutting
fluid [6,9].

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

In machining with MQL, the using of cutting fluid is reduced to as low as 500 ml h-1 [9,10]. In
conventional machining, generally, there is no control to achieve such a small volume rate.
Therefore, our group research made an effort to reach this goal. The designed MQL consist of a
mini-pump equipped with an injector and a sprayer. An Arduino-based controller controls the
spraying of cutting fluid. The controller can be either time- or temperature – controlled. In time-
controlled one, the cutting fluid is sprayed periodically. While in temperature-controlled, the
pump will gush the cutting fluid when the temperature of the tool reaches the set temperature
[11]. The temperature sensor is attached at the flank side of the tool about 3 mm from the tooltip
(Figure 1).
With the new MQL device, it reduced the consumption of cutting fluid [12], and smoother the
machined surface [13]. However, form chips formation it less advantage than using flood method
of cutting fluid [14]. The purpose of this paper is to observe the machinability in regards to
applying MQL from cutting tool point of view.

Figure 1. The MQL device arrangement in the lathe machine (modified from [12])

2. Methods
The machining process was carried out in a conventional lathe of GUT C236X1000. This machine
has nine spindle speed choices from a low speed of 34 rpm to a high rate of 1400 rpm. The cutting
fluid spraying mechanism is available in the machine tool. However, to achieve the MQL criteria,
we used our design. The MQL designed based on Arduino controller. It can be set at time-control
or temperature-control. In time-control one, the pump will spray the cutting fluid periodically
every 7 seconds, with 5 seconds spraying time, followed by 2 seconds off. In the temperature-
control, it set at 70 oC, when the sensor reached 70 oC the controller will send a signal to the pump
to start spraying, and it will stop when the temperature dropped down below this limit.

Table 1. Chemical composition of AISI 4340 [21]

Fe C Cr Mn Mo Ni Si P S
Bal. 0.37-0.44 0.7-0.9 0.7 0.2-0.3 1.83 0.23 0.035 0.04

A rod of medium carbon, low alloy steel AISI 4340 was used as the workpiece in straight
turning. It has mechanical properties of hardness and tensile strength of 95.9 HB and 110 N mm -2

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

respectively. The rod as received was 35 mm in diameter and was cut to 250 mm long. Figure 2a is
showing the workpiece illustration. We did not test this steel composition. However, according to
literature, its chemical composition is presented in Table 1.
We employed the tool insert of TiAlN PVD coated carbide for the experiments. It has an
agreement with ISO code DCMT11T304 [22]. It was completed with SM type chip breaker which
has a sharp cutting edge and a large rake angle. Figure 2b shows the picture and working
specification of the tool.
To simplify the number of experiments, we used Taguchi L9 design. Application of Taguchi in
machining experiments have proofed in reducing the number of trials [15] yet the optimum result
achieved with high-level confidence [16,17]. Instead of the method of cutting fluid application, two
other machining parameters were varied with three-level each. Table 2 describes variables and
levels variation in this research.

Figure 2. a) Workpiece dimension, and b) Insert tool specification

Table 2. The variables and levels in the experiments

Level
Code Factor control
1 2 3
A Depth of cut (mm) 1.6 1.8 2
B Composition 3:7 5:5 7:3
C Method Time-controlled Temperature- Flood
MQL controlled MQL

The depth of cut levels is within the working range of the tool for cutting medium carbon steel.
The composition means the volume comparison between pure cutting fluid as bough (which is

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

known as “dromus” among machining operators; and it will be used in this paper) and water in a
total volume of 1300 mm before application of the cutting fluid in machining. For example, the
composition of 3:7 means the mixed cutting fluid composes of 3 portions of the volume is water
and the rest is dromus. An arrangement of 3:7 comprises 400 ml of water and 900 mm of dromus
which were mixed before putting it in the reservoir. We used three methods of applying the
cutting fluid, two were using MQL with different control method, and one was a flood. Apart from
these three variables, some machining parameters were kept constant or in a statistical term is
known as control variables. They are spindle speed and feed rate of 585 rpm and 0.109 mm rev-1
respectively.
In applying the Taguchi L9 design, we used a new tool insert at every combination of
experiments. The experiment replicated three times for each combination to ensure the result.
Therefore, it will need 27 trials and 27 new tools. We observed the tools under an optic
microscope. We evaluation tools from three-point of views, viz. flank, right side rake and left side
rake. It evaluated according to the degree of deterioration and tiered into four levels.

3. Results and discussion

From tools observations, we categories the tool deterioration into four groups according to the
degree of its severities. Deterioration means every changing in the tool that deviates from its
original form. The first deterioration is scratch at the surface of the tool at either flank or rake side.
It may due to chips slide on the tool surfaces after being cut from the work piece [18,19]. The
second type of deterioration is surface tool burnt, which may be caused by hot temperature
emerged during machining. In some literature, the temperature may go up to 650 oC [17].
Therefore, it left the burnt mark on the tool surfaces. The third type of tool deterioration is a built-
up edge (BUE), an attachment at either surface of the tools. According to some references, BUE
will only be formed when machining workpiece that has two phases, e.g. [22], and steel are among
these materials. This BUE formation is a dynamic mechanism; that means the BUE formed and
collapsed continuously along during machining time [20]. Therefore, when machining is over, it
may leave some BUE on the tool surfaces at a different size. The formed BUE may affect the
machining process. The existing BUE may change the tooltip dimension and make the tool dull.
Consequently, it may be severe the machined surface roughness and initiate the extra force
needed to chips formation. The last deterioration is chipping of the tool. Inevitably, it is the worst
form of tool deterioration. It means the tool was no longer withstand the forces that work during
machining [18]. The chipped tool will create a rough machined surface, increase the machining
forces [18] and may damage the operator if kept working. Figure 3 illustrates the sample of four
types of tool deterioration.

Figure 3. Type of tool deteriorations

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

Figure 4. Some examples of how tool deterioration was rated

Following the above criteria, each tool is observed from three views; then, the degree of
deterioration of each device is an accumulation of three aspects of observation. Figure 4 portrays
some example of the evaluation result of the views. Table 3 expresses the L9 Taguchi design and
tool deterioration values. Some run of experiments results in maximum tool deterioration as
experiments 8 of the second replication and run 9 of the first replication. The next step is to
calculate the means of each experiment and put the results in the last column of Table 3. Means in
an average of three times replications. For example, means of run no one is presented in the
following calculation (equation 1).
1
𝑀𝑒𝑎𝑛𝑠 = ∑𝑟𝑖=1 𝑦𝑖 (1)
𝑛
5+4+5
Means =
3
Means = 4.66

In Taguchi design, the next step is to find the optimum factors. In machining, we hope as little
as the tool deterioration. Therefore, the quality criteria of “smaller the better” were chosen. The
means of means parameters and is levels presented in Table 4. Optimum (minimum) of means of
each parameter and level can be achieved at a depth of cut of level 1 (1.6 mm), composition level
1 (comparison between water and dromus 3:7) and method applying of cutting fluid level 3
(temperature-controlled MQL).

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

Table 3. Taguchi design L9 and the result of tool deterioration observations

No Controlled parameters Repli- Deterioration value Tot. Means
Depth Composition CF cation Left Right Flank Det.
of cut (water:dromus) method rake rake side Value
side side
1 1.6 3:7 Time- 1 1 2 2 5 4.66
controlled 2 1 1 2 4
MQL 3 2 1 2 5
2 1.6 5:5 Temp- 1 3 1 2 6 5.00
controlled 2 2 1 1 4
MQL 3 2 1 2 5
3 1.6 7:3 Flood 1 2 1 1 4 5.00
2 3 1 2 6
3 2 1 3 6
4 1.8 3:7 Time- 1 2 1 1 4 4.00
controlled 2 2 1 1 4
MQL 3 2 1 1 4
5 1.8 5:5 Temp- 1 3 1 2 6 7.66
controlled 2 3 2 1 6
MQL 3 4 4 3 11
6 1.8 7:3 Flood 1 1 2 1 4 4.33
2 1 2 2 5
3 2 2 1 5
7 2.0 3:7 Time- 1 2 2 1 5 6.00
controlled 2 3 3 2 8
MQL 3 2 2 1 5
8 2.0 5:5 Temp- 1 1 1 3 5 8.66
controlled 2 4 4 4 12
MQL 3 4 1 4 9
9 2.0 7:3 Flood 1 4 4 4 12 7.66
2 2 1 2 5
3 2 1 3 6

Table 4. Means of each factor

Means
Symbol Control factor Delta
Level 1 Level 2 Level 3
1 Depth of cut 4.88 5.33 7.44 2.55
2 Composition 4.88 7.11 5.66 0.77
3 Method 5.88 5.55 6.22 0.66
Average of Means 5.88

The optimum value of each level will be used as the controlled factors for confirmation
experiments. The optimum respond prediction value describes in the following calculation
(equation 2).
µprediction = (𝐴̅ 1 + 𝐵̅1 + 𝐶̅ 2) - y̅ (2)

6
iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

Where, Ā1, B ̅1 and C̅2 denote the minimum value of the tool deterioration as an effect of
depth of cut, cutting fluid composition and method of applying cutting fluid respectively. And
y̅ represents the average of means.
µprediction = (4.88 + 4.88 + 5.55) – 5.88
µprediction = 15.31 – 5.88
µprediction = 9.43

It is found that the average means prediction for optimal combination of tool deterioration is
9.43. Calculation of the confidence interval (CI) of the predicted average value of tool
deterioration according to the equation 3.
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑜𝑡𝑎𝑙 𝑒𝑥𝑝𝑒𝑟𝑖𝑚𝑒𝑛𝑡𝑠
Neff = 1+𝑛𝑢𝑚𝑏𝑒𝑟 𝑑𝑒𝑔𝑟𝑒𝑒 𝑜𝑓 𝑓𝑟𝑒𝑒𝑑𝑜𝑚 (3)
9𝑥3
Neff = 1+(2+2+2)
Neff = 3.85
𝐹(𝛼;1;𝑉𝑒) 𝑀𝑆𝑅𝑒𝑠
CI1 =√ 𝑁𝑒𝑓𝑓
𝐹0,05.2.2) 1,81
CI1 =√
3.85
19 𝑥 1.81
CI1 = √
3.85
CI1 = ± 2.98

Therefore, the value of the predicted average of tool deterioration confidence level of 95% is
9.43 ± 2.98 (6.45 ≤ � means ≤ 12.41). To know the contribution of each parameter, we calculate
the percentage of contribution of each factor. For example, the contribution of the depth of cut to
overall result is described in the following calculation (equation 4):
SS'A = SSA - MSe (DKA) (4)
SS'A = 11.18 – 1.81 (2)
SS'A = 11.18 – 3.62
SS'A = 7.56
𝑆𝑆 ͥ𝐴
ρA = x 100%
𝑆𝑆 𝑇
7.56
= 23.11
x 100%
ρA = 32.69%
Table 5 represents all of the calculation results. At the same time, Figure 5 is showing the graph of
contribution percentage.

Table 5. Contribution percentage

Symbol Factors SS’ Ρ
A Depth of cut 7.55 32.69 %
B Composition 5.00 17.30 %
C Method -2.96 12.82 %
R Residual 37.17 %
Total 100 %

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

Figure 5. Contribution percentage

Typically, in Taguchi method, the allowable error is 15%, which means that there were no
machining parameters ignored from the experiments. If the error is more than 50%, it means some
significant factors abandoned. The residual error in this research reaches 37.17%. According to
[16], the data still can be used as long as the error is less than 50% [21]. We believe that the error
comes from some factors which influenced the machining, but we kept this as constant, such as
cutting speed (represent by spindle rotation) and feed rate. Therefore, further analysis will use the
data. Another reason for the high error in this research may come from the temperature-
controlled MQL. The sensor position was 3 mm from the tooltip, while the maximum temperature
of the tool is at where the chips rub the flank face. Unfortunately, we could not place the sensor at
this place for a technical reason. Moreover, generated heat during machining distributed to the
chips, tool and workpiece at a percentage of 80%, 10% and 10% respectively [22]. Therefore, the
hottest temperature would is at the chips. For this reason, in temperature-controlled MQL the
temperature was set at 70oC to avoid overheating.
Depth of cut (DOC) contributes the highest to the tool deterioration at the level of 32.69%. The
deeper the DOC means the higher volume of materials should be removed (cut) at a time.
Therefore, a higher force needed. The higher the power employed, the hotter the machining
temperature at the tool-chips interface. In high temperature, the cutting fluids tend to evaporate
and make it less effective, and finally, it will weaken the tool shortly. It is evident that at DOC of
2.0 mm more possible to experience chipping than that of 1.8 and the least chance to chipping
when applying DOC of 1.6 mm. The result is contrasted with in case of drilling (boring), that depth
of cut did not affect the tool wear [23]. The different result maybe because of the diverse nature
between turning and boring process. In drilling, the depth of cut did not affect the radial cutting
force [9].
Composition of cutting fluid contributes to tool deterioration by 17.32%. The optimum
composition is 3:7. The more dromus, the more effective in protecting the tool deteriorate. In
cutting fluid, water predominantly for cooling purpose, while oil form dromus is for lubrication.
However, the more water composition, the easier the cutting liquid to evaporate. When the water
component evaporates, it forms oxygen [9] which will reduce the affinity between tool and
workpiece/chip. It is compound with the reduction of lubrication component from the dromus.
Therefore, a water-rich cutting fluid will reduce the capability of cutting fluid to protect from tool
deterioration. In the other hand, the ability of the pumping system of the MQL system should be
taken as a consideration. The dromus-rich cutting fluid means the more viscous, which
consequently make it more difficult to spray and may make the cutting fluid less effective. The

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iCOMERA 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1034 (2021) 012099 doi:10.1088/1757-899X/1034/1/012099

result is in line to that of Fernando et al. [21] that the less viscous cutting fluid result in smaller
droplets and have more penetration capability giving lesser friction at the tool flank face causing
lower flank wear. It is another proof that the pumping system in our MQL system is good enough
with the result a minimum tool deterioration with dromus-rich cutting fluid.
The cutting fluid application method is the least in affecting tool deterioration at the level of
12.82%. Either temperature- or time-controlled MQL gave better protection to the tool from
severe deterioration. The results in line with previous research [9,21]. In contrast, the flood
method results in some tool chipping. It may because the flood method would suddenly quench
the hot tool and make the tool more brittle. Whereas, a little amount of cutting fluid in the form of
mist from the MLQ sprayer would cooling the tool more gently. Finally, the temperature-
controlled MQL is the best alternative to reduce tool deterioration with a slightly different from
the time-controlled MQL.

4. Conclusions
The MQL device based on an Arduino controller has to succeed made, and its performance has
improved machinability from a tool failure perspective. The optimum combination which results in
minimum tool deterioration is by applying depth of cut of 1.6 mm, using a composition of water to
dromus 3:7, and applying temperature-controlled MQL. The prominent parameters should be
included as controlled variables in the experiments to reduce the error in analysis, such as cutting
speed and feed rate.

5. Acknowledgement
The authors would like to appreciate the Machining Laboratory of Mechanical Engineering
Department of Universitas Jember that has facilitated the research. Special appreciation to Mas
Deni Judas Priawan, the technician, who supervise the machining processes.

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