Enhancing machining performance of EN24 steel with CVD diamond coated tool and minimal quantity lubrication

Abstract

Abstract The research aims to investigate the effect of chemical vapour deposition (CVD) diamond coatings on cemented tungsten carbide (WC-Co) inserts when machining EN24 steel. In addition to the diamond coating, the research also incorporates the use of minimal quantity lubrication (MQL) technique during the machining process. The research involves experimental studies to evaluate the machinability characteristics of EN24 steel using tungsten carbide cutting inserts with diamond coatings and MQL. Diamond-coated tools are extremely effective in machining EN24 steel, particularly in applications requiring high precision, wear resistance, and long tool life. They are commonly used in industries such as aerospace, automotive, and manufacturing, where quality and durability of the machined components are critical. L12 orthogonal array was used to design experiments with the type of cutting insert used, test condition and cutting speed as control factors. Various parameters such as tool wear, cutting temperature and surface roughness were measured and compared with conventional machining techniques. The results reveal that average flank wear of cutting inserts decreased by 67.4% as a result of MQL when compared with dry machining conditions. Average flank wear decreased by 77.6% after diamond coating were applied compared with uncoated inserts. Diamond coated inserts subjected to MQL exhibit largest percentage reduction of 74.11% for surface roughness when compared to uncoated inserts. The average cutting temperature decreased by 53.09% due to MQL compared to dry machining.