Experimental investigation to study the effect of electrostatic micro-solid lubricant–coated carbide tools on machinability parameters in turning

Abstract

Conventional metal cutting processes involve massive consumption of energy where the specific cutting energy is usually high. A major division of this energy is converted into heat, which creates detrimental effects on cutting tool wear, surface quality of machined workmaterial and dimensional accuracy. Although cutting fluids are effective to coerce this energy transfer, the growing challenge to deal with the environmental and health aspects stood by coolant machining is imposing manufacturers to limit the usage of cutting fluids in current metal cutting practice. This research work introduces a new cutting tool, namely, electrostatic micro-solid lubricant–coated carbide tool with molybdenum disulfide as a solid lubricant. To exploit efficacies of newly developed electrostatic micro-solid lubricant–coated cutting tools in comparison with the uncoated cutting tools in machining processes, cutting forces, tool wear, chip formation and surface finish of machined workmaterial have been practically investigated. The results revealed that electrostatic micro-solid lubricant–coated tools performed much better as compared with that of machining with uncoated tools, and the adeptness of the electrostatic micro-solid lubricant–coated tools can make a potential alternative with additional benefits of being able to accomplish sustainable machining.