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Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software.

Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718.

A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously.

The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

It was verified that the micro-texture in the front and back of the tool at the same time had a positive effect on improving the milling behavior and surface quality of the tool. The purpose of this study is to explore the rationality of simultaneous placement of micro-textures on the front and rear surfaces of ball-end milling cutters, analyze the influence of micro-texture parameters on tool milling behavior and workpiece surface quality, reveal its internal mechanism, and obtain the best micro-texture parameters by optimization.

First, the mechanism of micro-texture is studied based on the energy loss model. Second, the orthogonal experiment is designed to analyze the influence of micro-texture parameters on tool milling behavior and reveal its mechanism by combining simulation technology and cutting experiment. Finally, the parameters are optimized based on the artificial bee colony algorithm.

The results show that the simultaneous placement of micro-texture on the rake face and flank face of the tool has a positive effect on improving the milling behavior and surface quality of the tool. Taking milling force, tool wear and surface roughness as the evaluation criteria, the optimal parameter combination is obtained: the rake face micro-texture diameter is 50 µm, the distance from the micro-texture is 200 µm and the distance from the cutting edge is 110 µm; the diameter of the micro-textured flank is 40 µm, the distance from the micro-texture is 170 µm and the distance from the cutting edge is 130 µm.

Taking milling force, tool wear and surface roughness as the evaluation criteria, the optimal parameter combination is obtained: the rake face micro-texture diameter is 50 µm, the distance from the micro-texture is 200 µm and the distance from the cutting edge is 110 µm; the diameter of the micro-textured flank is 40 µm, the distance from the micro-texture is 170 µm and the distance from the cutting edge is 130 µm, which provides theoretical support for the further study of the micro-textured tool.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2023-0022/

This paper aims to examine the performance of the machining parameters used in the hard-turning process of DIN 1.2738 mold steel and identify the optimum machining conditions.

Experiments were carried out via the Taguchi L18 orthogonal array. The evaluation of the experimental results was based on the signal/noise ratio. The effect levels of the control factors on the surface roughness and flank wear were specified with analysis of variance performed. Two different multiple regression analyses (linear and quadratic) were conducted for the experimental results. A higher correlation coefficient (R²) was obtained with the quadratic regression model, which showed values of 0.97 and 0.95 for Ra and Vb, respectively.

The experimental results indicated that generally better results were obtained with the TiAlN-coated tools, in respect to both surface roughness and flank wear. The Taguchi analysis found the optimum results for surface roughness to be with the cutting tools of coated carbide using physical vapor deposition (PVD), a cutting speed of 160 m/min and a feed rate of 0.1 mm/rev, and for flank wear, with cutting tools of coated carbide using PVD, a cutting speed of 80 m/min and a feed rate of 0.1 mm/rev. The results of calculations and confirmation tests for Ra were 0.595 and 0.570 µm, respectively, and for the Vb, 0.0244 and 0.0256 mm, respectively. Developed quadratic regression models demonstrated a very good relationship.

Optimal parameters for both Ra and Vb were obtained with the TiAlN-coated tool using PVD. Finally, confirmation tests were performed and showed that the optimization had been successfully implemented.

The purpose of this paper is to study the cutting performance of high-speed regime end milling of AISI 4340 by investigating the tool life and wear mechanism of steel using the minimum quantity lubrication (MQL) technique to deliver the cutting fluid.

The experiments were designed using Taguchi L9 orthogonal array with the parameters chosen: cutting speed (between 300 and 400 m/min), feed rate (between 0.15 and 0.3 mm/tooth), axial depth of cut (between 0.5 and 0.7 mm) and radial depth of cut (between 0.3 and 0.7 mm). Toolmaker microscope, optical microscope and Hitachi SU3500 Variable Pressure Scanning Electron Microscope used to measure tool wear progression and wear mechanism.

Cutting speed 65.36%, radial depth of cut 24.06% and feed rate 6.28% are the cutting parameters that contribute the most to the rate of tool life. The study of the tool wear mechanism revealed that the oxide layer was observed during lower and high cutting speeds. The former provides a cushion of the protective layer while later reduce the surface hardness of the coated tool

A high-speed regime is usually carried out in dry conditions which can shorten the tool life and accelerate the tool wear. Thus, this research is important as it investigates how the use of MQL and cutting parameters can prolong the usage of tool life and at the same time to achieve a sustainable manufacturing process.

This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).

Machining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.

The results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.

Inconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.

The literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

The purpose of this study is to investigate wear mechanisms of a multi-layered TiAlN/AlCrN-coated carbide tool during the milling of AISI 4340 steel under cryogenic machining.

The wear progression was measured using a toolmaker microscope and an optical microscope. Later, a field emission scanning electron microscope and energy-dispersive X-ray analysis were used to investigate the wear mechanisms in detail.

A comprehensive analysis revealed that the main causes of tool wear mechanisms were abrasion and adhesion wear on the flank face.

The investigations presented in this paper may be used by the machining industry to prolong the tool life at higher cutting speed by the application of liquid nitrogen.

The paper aims to study the wear and breakage characteristics of coated carbide cutting tools through micro-milling slot experiments on superalloy Inconel 718.

During the micro-milling process, the wear and breakage appearance on the rake face and flank face of the cutting tools, as well as the failure mechanism, have been studied. Furthermore, the wear and breakage characteristics of the micro-cutting tools have been compared with the traditional milling on Inconel 718.

The main failure forms of the micro tool when micro-milling Inconel 718 were tool tip breakage and coating shed on the rake and flank faces of the cutting tool and micro-crack blade. The main causes of tool wear were synthetic action of adhesive abrasion, diffusion wear and oxidation wear, while the causes of abrasive wear were not obvious.

The changing trend in tool wear during the micro-milling process and the main reasons of the tool wear are studied. The findings will facilitate slowing down the tool wear and prolonging the tool life during micro-milling Inconel718.

The results of this paper can help slow down the tool wear and realize high efficiency, high precision and economical processing of small workpiece or structure of the nickel-based superalloy.

A method extensively used in the production of optically flat and finely finished surfaces is that of lapping the surface upon a plate using a loose abrasive mixed into a slurry form with a carrying fluid. If the surfaces finished in this way are in continuous or intermittent sliding contact, it is the author's opinion that any abrasives retained in their surfaces will affect surface wear. This paper reported on some exploratory work to indicate the degree of embedment of abrasive in certain materials lapped by hand.

Green machining is becoming increasingly more popular due to concern regarding the safety of the environment and human health. The important implementation of stricter Environmental Protection Agency regulations associated with the use of ample amount of coolants and lubricants has led to this study on a new green machining technology with application of water vapor as coolants and lubricants in cutting Ni‐based superalloys and titanium alloy Ti‐6Al‐4V with uncoated carbide inserts (ISO Type K10). The purpose of this paper is to show that machining technology with application of water vapour could be an economical and environmentally compatible lubrication technique for machining difficult‐cut‐materials.

In this paper, the effect of water vapor applications in machining difficult‐cut‐materials have been investigated in detail, the cutting force, the chip deformation coefficient, the rake face wear and the width of tool flank land VB have been examined and analyzed, and a new green cutting technology is researched to machining Ni base superalloys and Ti‐6Al‐4V difficult‐cut‐materials.

The cutting force of machining Ni base superalloys and Ti‐6Al‐4V was affected by direct water vapor application, being lower than dry cutting and wet machining for all machining conditions; the Λh is the smallest with applications of water vapor as coolants and lubricants compared to dry cutting, pure water and oil water emulsion conditions the tool life extended by about six times than dry cutting, about four times than oil water emulsions at low cutting speed (ν_c<100 m/min), and about two‐four times than dry cutting, about two‐three time than oil water emulsions at higher cutting speed (ν_c>100 m/min) during machining Ti‐6Al‐4V with application of water vapor direct into the cutting zone.

The green cutting technology which applies water vapor as coolants and lubricants advocates a new method for machining difficult‐cut‐materials (Ni base superalloys and Ti‐6Al‐4V) without any environment pollution and operator health problem because the cutting force and chip deformation coefficient are reduced, the tool life is extended, and the tool flank wear can be decreased with applications of water vapor as coolants and lubricants to alleviate the adhering and diffusion wear compared to wet cutting and dry cutting.

New environmental legislation is forcing companies to realign their use of metalworking fluids in favour of non‐polluting cutting environments that will return acceptable tool wear rates and reduced costs. Studies have been undertaken to determine the effectiveness of various environments on tool wear, in order to either reduce or even eliminate totally, the dependency on flood coolants. Industrially reproducible cutting tests were devised, where an EN32 case hardening steel material was turned in a range of different cutting environments and tool life measured. Low oxygen gaseous environments were compared with conventional cutting environments and a 55 per cent flank wear reduction has been recorded using uncoated tooling.