Abstract
The role of cutting fluids in machining operations is crucial, impacting productivity, tool lifespan, and work quality. An experimental investigation was conducted on ball end milling of AISI 1040 steel using uncoated HSS tools under various coolant conditions and milling modes. The study encompassed four coolant conditions: dry, mist, 4% coolant concentration, and 8% coolant concentration, with constant cutting parameters. Machining performance was assessed based on tool wear and surface roughness. Results indicate a significant influence of coolant conditions on machining performance and surface quality. Mist coolant in down milling mode exhibited superior performance in terms of tool wear and average surface roughness (0.09mm and 0.462µm, respectively), followed closely by mist coolant in up milling mode, 8% coolant concentration, and lastly, 4% coolant concentration under up milling mode. Sustainability is becoming increasingly important as a decision attribute in the manufacturing environment. However, quantitative metrics for all aspects of the triple bottom line are difficult to assess. This paper considers sustainability metrics in tandem with traditional manufacturing metrics such as time, flexibility, and quality. The research underscores the importance of coolant selection and milling mode in optimising machining outcomes while highlighting the growing significance of sustainability in manufacturing decisions.