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Procedia Manufacturing 20 (2018) 377–385
Procedia Manufacturing 00 (2017) 000–000
2nd International Conference on Materials Manufacturing and Design Engineering
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2nd International Conference on Materials Manufacturing and Design Engineering

Comparative machinability performance of heat treated 4340 Steel
under drymachinability
Comparative and minimumperformance
quantity lubrication surroundings
of heat treated 4340 Steel
under dry
Manufacturing
Rabin and minimum
Engineering
Kumar Das*, Ashok
2017,
quantity
Society International
VigoKumar
lubrication
Conference
Sahoo,
(Pontevedra),
surroundings
2017, MESIC
Purna Chandra
Spain
2017, 28-30 June
Mishra
Ramanuj Kumar, Amlana Panda
Rabin Kumar Das*, Ashok Kumar Sahoo, Purna Chandra Mishra
Costing models for capacity
School of Mechanical Ramanuj
Engineering, optimization
Kumar,
Kalinga Institute of Amlana in Industry
Panda
Industrial Technology, 4.0: Trade-off
Deemed to be University,
Bhubaneswar-751024, Odisha, India
between used
School of Mechanical capacity
Engineering, and
Kalinga Institute operational
of Industrial efficiency
Technology, Deemed to be University,
Bhubaneswar-751024, Odisha, India
Abstract
A. Santana , P. Afonsoa,*, A. Zaninb, R. Wernkeb
a

Finish hard turning using coated acarbide

Abstract Universitytools of 4800-058
of Minho, various Guimarães,
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coating under different environments of
machining process has been raised as bUnochapecó, a new technique89809-000inChapecó,
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utilization layers of coating underTodifferent
industry. achieve aenvironments of
better life of the
machining process has been raised as a new technique in the field of machining by
insert and a better finishing the surface temperature at the cutting area must be controlled, which could be achieved report to the conventional
rectification
by machining andunder
to be extensively
MQL state.treasure-trove
Therefore anitsexperimental
utilization manufacturing
survey was industry.
conductedToonachieve variousa better lifeof
aspects of the
Abstract
insert and a better
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as wear the surface
of the inserttemperature
and average at the cutting
quality of area must be controlled,
the machined which could
surface utilizing be achieved
multilayer coated
by machining
carbide insert inunder MQL of
the turning state. ThereforeAISI
the hardened an 4340
experimental
under thesurvey
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aspects of hasthe
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machinability concept
such asof wear
multilayered"Industry
of the4.0",
coated insertproduction
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increasingly
utilizing
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in the scope of
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recommendedbased
in theon a real
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level time
of 1.6 thebasis
of microns and,
hardened
under necessarily,
AISI much themore
4340environments.
the two under efficient.
stateIt dry
wasand InMQL.
this context,
confirmed The thecapacity
thatdetailed optimization
investigation
abrasion has
is the main
goes beyond
revealed
mechanism the
thatof traditional
wear underaim
multilayered theofboth
coated capacity
carbide maximization,
insert
conditions has contributing
of generated
machining. a good also
Inserts for organization’s
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made quality profitability
and executed
of carbide multilayer theand
in coated value.
scope of
gave
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the lean
recommended management
level of and
1.6 continuous
microns under improvement
the two approaches
environments. It suggest
was capacity
confirmed
satisfactory performance in the MQL state in relation to the dry state. The surface finish was also higher in the MQL that optimization
the abrasion instead
is the of
main
maximization.
mechanism
condition ratherof The
wear
thanstudy
under
dry. of capacity
the both
Cutting speedoptimization
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the costing
most models
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imperative is made
an important
process of carbide
parameter research topic
thethat
multilayer
regarding deserves
coated
wear ongave
the
contributions
satisfactory fromthe
flank surfaceperformance
and both the
speed practical
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in predominates
the statetheoretical
inthe
on relation perspectives.
to theof
roughness dry ThisThe
thestate.
turned paper presents
surface
surface. finishand
was discusses a mathematical
also higher in the MQL
condition
model for rather
capacitythan dry. Cuttingbased
management speedonhas been the
different most models
costing imperative(ABC process parameter Aregarding
and TDABC). the wear
generic model hasonbeen
the
flank surface
developed andand the used
it was speedtopredominates on the roughness
analyze idle capacity of the
and to design turned surface.
strategies towards the maximization of organization’s
© 2017The
value. The trade-off
Authors. Published by Elsevier B.V.
capacity maximization vs operational efficiency is highlighted and it is shown that capacity
© 2018 The Authors. Published by Elsevier B.V.
Peer-review
optimization under
might responsibility
hide operational of the scientific
inefficiency. committee of the 2nd International Conference on Materials
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Manufacturing
©
© TheAuthors.
2017Engineering.
2017
Design The and Published
Authors. Design Engineering.
Published by by Elsevier
Elsevier B.V.B.V.
Peer-reviewunder
Peer-review under responsibility
responsibility of scientific
of the the scientific committee
committee of the 2nd International
of the Manufacturing EngineeringConference on Materials
Society International Conference
Manufacturing
Keywords:
2017. andMQL,
Flank wear, Design Engineering.
Surface finish, Chip morphology.

Keywords: Cost
Keywords: FlankModels;
wear, MQL,
ABC;Surface
TDABC; finish, ChipManagement;
Capacity morphology. Idle Capacity; Operational Efficiency

1. Introduction
* E-mail address: rabin.kumar88@gmail.com
The cost of idle capacity is a fundamental information for companies and their management of extreme importance
* E-mail©address:
2351-9789 2017 Therabin.kumar88@gmail.com
Authors. Published by Elsevier B.V.
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
in several
Design ways:
Engineering.
2351-9789
tons of production, available hours of manufacturing, etc. The management of the idle capacity
© 2017 The Authors. Published by Elsevier B.V.
* Paulo Afonso.
Peer-review Tel.:
under +351 253 510of
responsibility 761;
thefax: +351 253
scientific 604 741 of the 2nd International Conference on Materials Manufacturing and
committee
E-mail address:
Design Engineering.psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.055
378 Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385
2 Das et al./ Procedia Manufacturing 00 (2017) 000–000

1. Introduction

Machining of heat treated hardened steel component with hardness 50±1 HRC, has gain immense popularity as a
novel alternative to typical grinding operation is a cost-benefit and a malleable machining process for metal
component containing ferrous element. Turning of hard to cut materials has been made easy with evolution of
superior cutting tool material and distinctive coating technology which produce cutting inserts having superior
hardness value, resistant to wear and chemical balance of the coatings which offers confirm perks in case of life of
the cutting insert and machining achievement. Machining in dry environment is the suitable condition to perform
hard turning operation, as maximum amount of heat is generated which helps to soften the upper surface of
hardened steel, hence making machining easy. But the chunk of heat produced at the insert and work material
interaction zone needs to be controlled, so as to minimize wear on tools flank surface and protecting the work piece
surface from experiencing unwanted residual stress which could lead to failure of the work material. So as to face
this major challenge in hard machining divergent lubricating techniques were introduced which replaced traditional
flooded lubrication technique, which in hand helped in cost cutting of overall machining cost by eliminating
excessive use of lubricant and also help in creating an environment friendly machining condition. Minimum quantity
lubrication (MQL) is one among the divergent lubricating technique which researcher across the scientific fraternity
are putting their efforts in investigating its impact in area of hard machining. Attanasio et al. studied that by
reducing the use of cutting fluid in machining many advantages like worker’s safety, environmental and cost
effective benefits were obtained. It was found that when minimum quality lubrication was applied to tool surface,
life of the tool enhanced [1]. Rao et al. stated that use of solid lubricants in turning have better results over
traditional fluids used in machining. It improves overall process achievement by reducing machining forces and
wears at tool surface and provides better surface finish. [2]. Elmunafi et-al observed that the performance was better
during MQL using castor oil as machining fluid over dry machining during machining of heat treated stainless steel.
By using MQL the life of the tool was longer as compared to dry machining. Roughness of the surface and forces
involved in cutting also boosted minimally as a result of decrease in temperature generated in the machining zone.
[3]. Weinert et al. concluded by using MQL processes are highly productive and higher performance was archived
with slight reduction in production time. Dry machining is mainly suitable for large scale industries where
production is very large. Betterment in research technology and increasing number of industrial application in field
of dry machining and MQL would expand its use in small and medium sized manufacturers [4]. Dhar et al.
experimented the mechanical output of dry lubrication with MQL for turning of 1040 grade steel by measurement of
machining forces, tools wears, chip reduction co efficient, machining temperature, surface and deviation of
dimension. It was found that by using near dry lubrication resulted in lower machining force, decrease in tool wears,
surface roughness and dimensional deviation [5]. Dhar et al. experimented the outcome of MQL on temperature of
cutting zone, quality of turned product and formation of chip in turning 1040 grade steel at divergent speeds and
axial feed sequence using uncoated carbide tool. By using MQL machining better cutting performance, decrease in
cutting temperature and improved chip tool interaction, better dimensional accuracy was found compared with
conventional machining [6]. Netake et al. predict the forces involved in cutting operation and surface quality while
hard turning of heat treated alloy grade steel by MQL employing PVD coated nano crystalline TiSiN-TiAIN coated
carbide tool. The models were reliable and could be used exclusively to predict the machining forces and surface
roughness as correlation coefficient found was 0.9 [7]. Liang et al. compared the mechanical performance of MQL
for turning hardened bearing grade steel materials using completely dry lubrication method. It was observed that the
surface roughness, temperature during cutting operation decreased, tool flank wear was delayed but it also had a
minimal effect on the machining forces [8]. Khan et al. described the effect of MQL performance related to finish
hard turning of low alloy correlated with dry cutting and wet cutting while using vegetable oil based cutting
lubricant. Up to 10% reduction in average chip tool interface temperature was found using MQL system. Chips
surface appeared much brighter and smoother in case of MQL and build up edge formation was absent. Using MQL
system tool wear was greatly reduced and surface finish had improved [9]. Vyas et al. discussed the cause for the
formation of saw tooth chip in metal cutting. Saw tooth chip formed when very hard and brittle materials were
machined at high speed and feeds. This formed due to thermal origin and cyclic cracking in the original surface.
Gross cracks and micro cracks were involved in saw tooth clip formation [10]. Jain et al. discussed the various
advantages of MQL over flooded cooling. Longer tool life, improved surface quality, better chip formation, decrease
in cutting temperature and reduction in machining force was obtained using MQL [11]. Kumar et al. experimentally
analyzed the surface quality of finished product under MQL and wet conditions. Surface quality improves from 7-
 Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385 379
Das et al./ Procedia Manufacturing 00 (2017) 000–000 3

10% under MQL condition when compared to flooded lubrication. Surface finish was enhanced as a result of low
tool wear in MQL condition [12].

2. Experimental Details

In this paper AISI 4340 heat treated hardened steel of 50±1 HRC was selected in shape of cylindrical bar with initial
length of 180 mm and un-machined diameter of 40 mm as test material for hard turning operation. The turning
operation is performed with machine tool which is CNC lathe installed with Fanuc controller shown in Fig. 1. (a). In
this experimental investigation commercially accessible MT PVD multilayer coated carbide insert with external
Al2O3 layer were employed having geometrical significance of CNMG120408 shown below in Fig. 1. (b). Tool
holder having geometry PCLNR2525M12 was employed in this test for mounting the selected insert.

a b

Fig. 1. (a) CNC machine tool with MQL set up; (b) MT PVD coated carbide insert

Turning operation was carried out in dry machining condition and MQL machining condition. The lubrication
method employed in this test was minimum quantity lubrication (MQL) set up which was manufactured by
DROPSA, Italy and utilizes Iron aluminium oil LRT 30 as lubricant which is mixed with air supplied from the
compressor. In this experimental study the air and oil mixture is used at 5 bar pressure and 50 ml/hr flow rate to be
supplied at the cutting region through a nozzle having a fixed stand-up distance between tool tip and nozzle. The test
responses (flank wear and surface finish) are the two most important criteria which are to be investigated which
have direct effect on life of the tool and quality of finished product.

a b

Fig. 2. (a) Flank wear measurement set up; (b) Surface roughness tester

Study of wear at the flank surface and to measure the extent of wear the optical image of cutting insert after finish
turning was captured with the help of Olympus STM6 optical microscope equipped with SC 30 camera and image
380 Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385
4 Das et al./ Procedia Manufacturing 00 (2017) 000–000

analyzer software made in Japan displayed below in Fig. 2. (a). All the micrographs were taken at 50x magnification
(5x objective and 10x eyepiece) and flank wear criteria is fixed at 0.3 mm. Surface finish which is the measure of
surface quality after machining operation which denotes the quality of a finished product. Surface finish standard
criteria was at 1.6 microns. The arithmetic surface roughness average was recorded by the Taylor Hobson (Surtronic
25) surface finish instrument shown in Fig. 2. (b), confer to ISO 4287 standard in which assessment length as well
as cut-off length was fixed at 4 mm and 0.8 m. The schematic diagram below in Fig. 3 shows the overall test carried
out in this paper.
Hard machining

Selection of
process parameters
Selection of tool Selection of
and work piece cutting condition

Hard turning

Responses

Surface finish
Tool wear

Fig. 3. Schematic diagram of experimental investigations

3. Result and discussion

In these section actual findings of the test runs are summarized. In this paper all the test runs are conducted in twain
dry and MQL environments and scrutiny of major responses like wear on the flank surface and surface roughness of
the work piece were reported accordingly.

3.1. Tool wear analysis

The parametric effect of wear at the flank surface and its mechanism in the process of turning of hardened steel in
each test run have reported in this section. It has been recognize that value of wear on the flank surface dose not
exceeds 0.3 mm criteria even at higher speed when machining is performed under both dry and minimum quantity
lubrication (MQL) cutting condition with multi-layered coated carbide cutting insert. Taking into account the
process of tool wear is basically dominated by two mechanisms namely abrasion and diffusion. Here in these
successive test runs abrasive is the principal wear mechanism in the investigated range. Other mechanism like
chipping and catastrophic failure of the cutting edge was not observed when machined with multi-layered coated
carbide insert.
Machining under dry cutting condition revels that growth of wear at the flank surface of the insert increases with
increase in cutting speed. Experimental output suggest that with linear escalation in speed range of (100 m/min up to
200 m/min) value concerning wear at flank surface has positive growth of (0.062 mm to 0.135 mm), expect at speed
value of 50 mm/min the wear value is noted to be 0.066 mm which is due to the higher value of feed of 0.08 mm/rev
as exhibited in the Fig. 5. (a-d).
 Das et al./ Procedia Manufacturing 00 (2017) 000–000 5
Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385 381

Machining under minimum quantity lubrication (MQL) confronts very lesser values of wear at the tools flank
surface as compared to machining under dry condition at similar parametric settings. The experimental trials revels
that with linear escalation in speed from (100 m/min up to 200 mm/min) wear at the flank surface takes a positive
growth (0.049 mm to 0.086 mm), but at 50 mm/min speed parametric setting the wear value is noted to be 0.052 mm
which is due to an higher feed rate value accompanied with low cutting speed as shown in Fig. 5. (e-h). According
to experimental result presented in Fig. 4, the compression between tool wear of dry and MQL shows that
enhancement of speed cause growth in wear at flank surface and orthogonal turning under MQL condition produces
lesser wear at flank surface than dry cutting condition.
According to findings of experimental investigation it was quite apparent with linear enhancement in speed
machining under both the environments the frictional force at the cutting insert chip and work material tool interface
increases, which eventually elevate the temperature at that cutting zone as a result of which coating on the tools
surface starts to degrades giving rise to wear at the flank surface and abrasion was the primary wear phenomenon
observed. Similar findings were reported by Chinchanikar and Choudhury [14].

3.2. Surface roughness analysis

Surface finish is the primary quality check standard of a material surface quality after undergoing machining. The
parametric aftermath of surface finish in the process of hard turning of hardened steel in each experimental trail has
been reported accordingly. It has been noticed that in both the cutting environments even at higher feed rates surface
roughness value dose not exceeds the criteria of 1.6 microns when machined utilizing multi-layered coated carbide
inserts.
Machining under dry environment suggest that at higher values of feed rate the surface roughness value too
increases. There is a linear growth in surface roughness is experienced when feed value enhances between (0.4
mm/rev - 0.16 mm/rev). Speeds as well as depth are the least affecting process parameter in case of surface finish,
while feed plays the role of significant process parameter.
Machining under minimum quantity lubrication (MQL) encounters lesser surface roughness values as compared
with the machining under dry condition with identical parametric settings. Experimental investigations suggest that
with linear increment in feed value between (0.4 mm/rev - 0.16 mm/rev) finish quality of turned surface value
simultaneously enhances. Here feed is the compelling process parameter influencing quality of surface finish,
pursued by speed and depth.
Thus from experimental trails it was concluded that finish turning in MQL condition provide superior finish of the
work surface when compared along dry condition as lubricant used in MQL reduce the friction alongside that help to
flush out the chip concentrated at machining zone which in turn assist in lowering the temperature at machining
zone and lower surface roughness values. Similar analysis was also done by Varadarajan et al. and Sanjeev kumar et
al. [12-13].

0.14 Dry
MQL
0.12
Flank Wear, VBc (mm)

0.10

0.08

0.06

0.04

0.02

0.00
0 30 60 90 120 150 180 210
Cutting speed, v (m/min)

Fig. 4 Graph presenting comparison between tool wear in dry and MQL conditions
382 Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385
6 Das et al./ Procedia Manufacturing 00 (2017) 000–000

a e

VBc = 0.062 mm VBc = 0.049 mm

v = 100 m/min; f = 0.04 mm/rev; d = 0.2 mm v = 100 m/min; f = 0.04 mm/rev; d = 0.2 mm

b f

VBc = 0.066 mm VBc = 0.052 mm

v = 50 m/min; f = 0.08 mm/rev; d = 0.2 mm v = 50 m/min; f = 0.08 mm/rev; d = 0.2 mm

c g

VBc = 0.135 mm VBc = 0.086 mm

v = 200 m/min; f = 0.12 mm/rev; d =0.2 mm v = 200 m/min; f = 0.12 mm/rev; d =0.2 mm

d h

VBc = 0.085 mm VBc = 0.071 mm

v = 150 m/min; f = 0.16mm/rev; d = 0.2 mm v = 150 m/min; f = 0.16mm/rev; d = 0.2 mm

Fig. 5 Optical micrograph of flank wears (a-d) dry condition (e-h) MQL condition
 Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385 383
Das et al./ Procedia Manufacturing 00 (2017) 000–000 7

4. Chip morphology

a e

v = 100 m/min; f = 0.04 mm/rev; d = 0.2 mm v = 100 m/min; f = 0.04 mm/rev; d = 0.2 mm

b f

v = 50 m/min; f = 0.08 mm/rev; d = 0.2 mm v = 50 m/min; f = 0.08 mm/rev; d = 0.2 mm

c g

v = 200 m/min; f = 0.12 mm/rev; d =0.2 mm v = 200 m/min; f = 0.12 mm/rev; d =0.2 mm

d h

v = 150 m/min; f = 0.16mm/rev; d = 0.2 mm v = 150 m/min; f = 0.16mm/rev; d = 0.2 mm

Fig. 6 Optical micrograph of chip at (a-d) dry condition (e-h) MQL condition
8384 Das et Kumar
Rabin al./ Procedia
Das etManufacturing 00 (2017) 000–000
al. / Procedia Manufacturing 20 (2018) 377–385

Investigation of chip morphology is a crucial facet in machining of hard to cut material when machined in two
different cutting environments. A vast amount of heat is generated at tool work piece interface which of which a
major amount of that heat is being carried away by chips. So it is important to study chip morphology of each chip
collected in experimental trails based on its colour and shape.
Machining under finished dry turning condition encounters helical and ribbon shaped chip. At lower speed (50
m/min) ribbon shaped chip is formed, while at speed value from (100 m/min to 200 mm/min) helical chips were
produced. Considering colour of the chips metallic and burnt blue coloured chips were reported. At higher feed and
speed parametric combination (0.16 mm/rev and 150 m/min) we can see brunt blue coloured chip, while in all other
parametric setting metallic coloured chips were observed.
Experimental trials under minimum quantity lubrication condition only faces helical shaped chips at all parametric
settings. Taking colour of the chips into consideration metallic and blue colour chips were being reported in all
experimental trials. Blue coloured chip are observed at lower feed and speed parametric settings (0.4 mm/rev and
100 m/min) and rest all chip are metallic in colour.
From the experimental trials and optical micrograph of chip shown in Fig. 6, it was concluded that when lubricant is
used even at higher feed and speed parametric condition the colour of the chip remain metallic as it is, while
machining without lubricant the chip colour changes from original metallic colour into brunt blue. Here in minimum
quantity lubrication some chunk of heat is also borne off through lubricant involved in the cutting zone. In every
experimental trail there is element of saw tooth chips which are formed due to the cyclic fracture taking place during
machining which aims towards plastic deformation of material from the work piece surface. Similar results observed
by Shaw and Vyas [11] and Mhamdi et al [16].

5. Conclusion

 Performance of multi-layered PVD coated carbide insert on AISI 4340 heat treated steel in finish hard turning
under both the cutting environments were characterized by stable machining operation without any tool fail and
defects like chipping or catastrophic failure.
 The flank wear value also remained with the limit of 0.3 mm criteria. Machining under dry conditions
encountered high tool wear values as compared to machining under minimum quantity lubrication condition. In
both the machining condition wear at the flank surface is predominated by cutting speed identical findings was
reported by Das et al. [17]. But feed dominates the surface finish values for both in dry and minimum quantity
lubrication conditions. Similar findings are presented by kumar et al [12].
 Wear at the flank surface with maximum value were reported in dry condition, whereas in other hand minimum
quantity lubrication has encountered lesser wear values than dry condition.
 Excellent surface finish values were being reported in MQL when correlated with dry condition in each
experimental investigation, due to reduction of friction alongside lower temperature at cutting zone and rapid
flushing out of chips. Similar conclusions were drawn by Varadarajan et al. and kumar et al. [12-13].
 Chips formed in all experimental trails were strongly influenced by feed value and heat produced at the cutting
zone. In MQL condition helical shaped chips are formed, with metallic and blue colour chips. While in dry
condition helical and ribbon shaped chip were encountered having metallic and burnt blue coloured chips. At
higher feed and speed value the heat at the cutting zone is increased that result in burnt blue colour chip in dry
machining. Continuous and saw tooth chips are found throughout the experimental trails which indicates to the
characteristics of hard turning.

Acknowledgements

This research is supported by Department of Science and Technology New Delhi, India under SERB project (Grant
No. SB/S3/MMER/0054/2013). The authors express their gratitude and thank DST, SERB for granting financial
support to carry out the research work.
 Rabin Kumar Das et al. / Procedia Manufacturing 20 (2018) 377–385 385
Das et al./ Procedia Manufacturing 00 (2017) 000–000 9

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