Investigation of the effects of MQL and material hardness on energy consumption, vibration, and surface roughness in hard turning of AISI 52100 steel for a sustainable manufacturing

Abstract

Turning hardened steels is more advantageous than cylindrical grinding. However, the machinability of hardened steel is difficult. Therefore, in this experimental study, two different AISI52100 steels with 45 and 50 HRC were machined with varying cutting parameters (feed rate: 0.15, 0.25, 0.35 mm/rev; cutting speed: 140, 155, 170 m/minute; depth of cut: 0.08, 0.12, 0.16 mm) under three different cooling conditions (dry, coolant, and MQL). According to the experimental result the lowest surface roughness, vibration, and energy consumption were obtained in cutting with MQL. With increasing feed rate and depth of cut, vibration, power consumption, and surface roughness increased, while energy consumption decreased because the machining time was shortened. With increasing cutting speed, surface roughness, tool vibration, and energy consumption decreased, while instantaneous power consumption and chuck vibration increased. For the lowest energy consumption, surface roughness, vibration, and highest machine tool performance for the ideal cutting condition, high hardness (50 HRC) using MQL, high cutting speed (145 m/minute), low feed rate (0.1 mm/rev), and high depth of cut (0.3 mm) should be preferred. Thus, 3.88% energy consumption, 58.25% surface roughness value, 10.06% chuck vibration value, and 28.80% tool vibration have decreased according to the average cutting conditions.