Bonfring International Journal of Industrial Engineering and Management Science, Vol. 6, No.
4, October 2016 140
Experimental Investigation of Tool Wear of Single Point
Cutting Tool Insert Using Different Lubricants: A
Comparative Study
C. Ramesh Kannan, P. Padmanabhan and G. Arundeepan
Abstract--- In present investigation, the effect of
lubrication on tool wear of single point cutting tool insert. The
AISI4340 steel is turned with single point cutting tool insert
with different lubricant Dry, Minimum Quantity Lubrication
and Nano. Speed, feed, depth of cut are the input parameters
at three levels and crater wear are considered as output
response. On comparing these lubricants, Nano fluids seem to
exhibit a better novel property that made it applicable to use it
as a heat transfer medium in cutting zone. As a result carbide
cutting tool insert with Nano lubrication have superior wear
resistant followed by the Minimum Quantity Lubrication and
Dry.
Keywords--- Tool Wear, Lubricants, Turning Process.
I. INTRODUCTION
HE metal cutting is the major task. (Richard Harvert.
T 2014) [1] It deals with the Surface Roughness as
important as geometry and or Mechanical property of
Material. The desired functional and frictional behaviors were
described in a better way by skewness (Rsk) and kurtosis
(Rku) as statistical parameters of surface roughness rather than
average roughness (Ra) and surface height (Rz). Statistical
parameters of Surface had been analyzed in mass production
of aluminum alloys by turning process shows it only on tool
Geometry. (Milos Madic 2011) [2] Produced the predictive
modelling and optimization of machining process. By Using
ANN prediction method the Cutting force components using
high prediction accuracy. Depth of cut feed rate influence
main cutting force, feed force, passive force positively and
Cutting edge angle influences cutting force directly. The feed
force negatively. (M. Grzesik. 2005) [3]. Dealt with green
manufacturing that include dry and hard, often high-speed,
machining Technology. With lower values of skew at lower
feeds, surfaces generated experiences better bearing
properties. Wiper inset had Comparable surface roughness to
the effect at lower feed rate (A. Esteves Correiam 2011) [4].
Used machining technology on Surface roughness and find
C. Rameshkannan, Faculty, Department of Mechanical Engineering,
Anna University Regional Campus, Madurai, India. E-mail:
rameshkannan@autmdu.ac.in
P. Padmanabhan., Professor, Department of Mechanical Engineering,
V.V College of Engineering, Tisaiyanvilai. India. E-mail:
ajaipalani@yahoo.co.in
G. Arundeepan, P.G Scholar, Department of Mechanical Engineering,
Anna University Regional Campus, Madurai, India. E-mail:
arun.deepan66@gmail.com
DOI:10.9756/BIJIEMS.7622
ISSN 2277-5056 | 2016 Bonfring
that conventional insert to the wiper insert as a significant
class of cutting tool to give effective surface roughness by
different amplitude parameters. High feed rate of cutting tool
with inserts give micron level machined surface and provide
similar surface roughness when compared to conventional
insert. (Erween A. Rahim and Hiroyuki sasahara 2010) [5],
Compared the palm oil and synthetic ester on surface integrity.
That result in MQL has more benefit in palm oil on Surface
properties. The mechanical property of machined surface has
altered but Hardness is increased than bulk material hardness.
The palm oil is better than SE in terms of micro-hardness and
effective lubrication and cooling due to high viscosity (Y.M
Shashira. 2010) [6]. Say vegetable oil and soya bean,
sunflower oil and rapeseed had relevant properties as cutting
fluids. To increase these properties the poor low temperature
property and resistance to oxidative degradation by additives,
chemical modification and generic modification is done. The
result were attained under metal working condition and
studied oils revealed that the vegetable oil have large scope of
utilization. (Khaider Boucha 2014) [7]. worked on the
experimental study on hard turning of steel the process
parameters and performance characteristic were optimized
using ANOVA, generic algorithms, Gray taguchi methods and
statistical analysis and showed that statistic and stochastic
approaches bring reliable methodologies to improve the hard
turning process and they are very suitable for solving the
optimization problem with multiple performances. (Kennth M.
Doll 2011) [8]. proposed work on chemically modified
vegetable oil using surfactant system and found that epoxidase
oil is stable oil in water. The best surfactants have HLB value
slightly above. He concluded that, drops of the stabilized
emulsion are extremely smaller in all cases though those
emulsions had similar stabilities as inspected visually. Thu
studies have demonstrated that emulsion stability is not always
correlated with droplet size, but dependent on many other
factors like oils are highly effective lubricants, even at only
1% oil. This shows that of all of the lubricants in the system,
only the small amount of lubricant at the surface gives the
wear reduction where the emulsion acts as the delivery
system. (D.I lalwani 2008) [9]. presented the effect of cutting
forces based on response surface methodology on turning of
steel. The coated ceramic tool shows main contribution of
cutting parameters, the feed force, thrust force, cutting force
model and surface roughness model. While cutting speed and
depth of cut are feed nearer their high level of desired range
and feed rate is at low level of the experiment range better
surface roughness can be attain. (Kuan-Ming li, Shih-yen
Chou 2010) [10]. present performance of minimum quantity
lubrication technique in Nano also known as near dry
Bonfring International Journal of Industrial Engineering and Management Science, Vol. 6, No. 4, October 2016
machining refers to cutting fluids in tiny quantity. He
compared MQL and Complete Dry conditions were to give
better mechanical performance. Result were Reduction in
flank wear length on all cutting conditions and expected to
improve tool life. Surface roughness measurement when
milled on steel show. Minimum quantity lubrication shows
better surface roughness in terms of dry cutting. The
relationship between tool wear and burr formation, diminution
under MQL condition is attributed to low wear in Nano-
cutting .The increase in oil mist velocity and reduction of oil
drop size achieved by effect of air flow rate in micro-milling
under MQL.(R. Ferreira 2015) [11]. Researched Wiper
geometry has as main objective obtained a smoother surface
after the cutting process. There is no leaning for surface
roughness while analyzing have slightly better performance of
wiper tools was observed for the flank wear. The results varied
widely depending on the machining length. Flank wear and
surface roughness showed no relation. The flank wear was
measured in the corner of the tool using the indicator VBC. No
catastrophic failure was obtained during the tests. Some tools
had evolution of the surface roughness tends to reach higher
values when tool wear is higher. (VinayakNeelakanthGaitonde
2010) [12]. conducted comparison between different
performance parameters of cold work tool on turning with
different ceramic inserts. Tool wear had high sensitive to
cutting speed and feed rate and it have been compared with
wiper insert. Ceramic insert has an edge over the other tool for
minimizing wear. Comparison of wiper ceramic insert and
conventional insert minimize the specific cutting force
irrespective of the feed rate. (Sunday Albert Lawal 2013) [13].
considered cooling application and its importance high
temperature generation on the edge of the cutting edge has
controlling on influence on wear rate of cutting tool and
connection of friction between chips. The amount of heat loss
depends on thermal conductivity of tool, tool shape and
cooling method. Small reductions in temperature greatly
increase tool life. The heat carried from the cutting zone is
decreased in use of cutting fluid. Thus result show that
cryogenic cooling technique gives improved productivity and
product quality. The performance of MQL in machining
process gives better result especially when use of vegetable oil
Babur (Ozcelik 2011) [14] done optimization of surface
roughness and performance of four cutting oils and vegetable
oil on drilling stainless steel. The performance evaluation of
vegetable based cutting oils shows give grate result, compare
to semi-synthetic oil along with mineral based fluids by
surface measurement. The spindle speed has less influence on
surface in drilling but increase in spindle speed gives decrease
in surface roughness. (Iturbe 2016) [15]. Conducted cryogenic
machining with MQL is better surface integrity by permitting
alternate to flood cooling since large amount of cutting fluids
along with improve functional performance of machined
component. Study of cutting fluid with liquid nitrogen with
MQL compared to conventional cutting fluid show that tool
life achieved it cryogenic and MQL machining for long term
in turning operations produce hard surface layer deeper than
one induced in conventional machining leads to tool life and
poor surface integrity in surface roughness micro structural
damage with conventional cooling.
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141
(R. suresh 2012) [16].Studies conducted on hard turning with
multicoated carbide tool to get reduced processing cost,
increase in productivity and material property. The abrasion of
tool in all cutting condition was principle wear. Thus resulted
in the feed rate had physical as well as statistical influence on
machining force. The sufficient chip formation process cant
be achieved for particular cutting force to machining followed
by the depth of cut, cutting speed,low feed rate.The multiple
regressions were obtained to predict tool wear and surface
roughness. (N. talib, E.A Rahim 2016) [17]. Researched on
effect of tribological behavior of metal working fluid is reduce
wear and friction. It made from mineral oil cause ecology and
human health. By Minimum quantity lubrication had done for
lubrication in orthogonal cutting processing for MJO5. It gives
better cutting force compared to synthetic Easter CJO need to
undergo chemical modification process in order to affects the
thermal and oxidation stability. (Prernasingh Chauhan, V.K
Chhibber 2013)[18]. Discussed about non-Edible oil as a
source of biolubricants found that have great importance on
the emphasis on environmental friendly lubricant. The
ecofriendly vegetable oil compared by property of synthetic
Easter, chemically modified Easter to get increased
performance on hydraulic oils, refrigeration oils, chainsaw
lubricants. Most mineral oil based greases had been
formulated easily from vegetable oil based thickener and
stabilized vegetable oils. (S.A lalwal, 2013) [19]. proceeded
with development of formulation of vegetable oil-based
networking fluids in turning process. The wear in turning
process by fluids deployed by parameters as thrust force,
surface roughness, temperature at tool chip interface,
Lubrication and cooling are severe on contact process by
machining workpiece. Utilization of vegetable oil chemistry of
petroleum-based fluids was positive development. If a fluid
has excellent biological and hard water stable shown to be
unique for many characteristic of lubrication. (Arjun kumar
2015) [20]. conducted critical assessment of lubrication
technique and give performance and drawback. A colloidal
mixture of metallic or non-metallic Nano meter sized particles
in a base fluid is called. The Nano fluid (NF) shows to be
mixture of metallic or non-metallic Nano meter sized particles
by collusion the atoms. In the present work, a Nano fluid with
superior thermal and tribological properties is developed by
mixing TiO2 nanoparticles in vegetable oil-water or different
machining condition is high lightened that includes minimum
quantity lubrication using vegetable oil lubricant. Resulted in
improved surface roughness of 31% for MQL with vegetable
oil lubricant the analysis of surface integrity titanium alloy
with carbide coated shows no significant difference between
MQL and conventional method.
The main objective of this investigation of tool wear using
single point cutting tool insert at different lubrication done
during turning of AISI4340 steel. The process parameters are
speed feed and depth of cut are selected as three levels. In this
study, effects of feed rate, depth of cut and cutting speed are
given as input parameters to find the cutting force using
CNMG120408SMRH13A cutting tools under rough condition.
This paper has four sections. The first one deals the
experimental details of machining, which includes the
preparation of work materials, machine setup and machining
of work material. The third section comprises modeling by
Bonfring International Journal of Industrial Engineering and Management Science, Vol. 6, No. 4, October 2016 142

using Response Surface Methodology. The last one analysis Ring Light (White LED)
includes the simulations and optimization. Dimension & 316 x 455 x 533 (W x D x H), 40 kg
Weight
II. EXPERIMENTAL DETAILS Input Voltage 100 240
Range V (Max. 1.8 A)
A. The Preparation of Work Material
C. Experimental Setup
AISI4340 is selected as work material the shape of 32 mm
diameter, 200mm long. After sizing the work material Table 2: Parameters and their Level
polished by emery paper. Sl.no Parameter/notations/units Parameter Levels
-1 0 1
B. Tool Materials
1 Cutting Speed(N) in rpm 1000 1250 1500
The CNMG120408SMRH13A is selected as single point 2 Feed rate (f) in mm/rev 0.1 0.2 0.3
cutting tool insert during machining of AISI4340 steel. The 3 Depth of cut(d) in mm 0.3 0.4 0.5
schematic diagram of prepared work material sample and The value for flank and crater wear from the experimental
insert are shown in Fig.1. test is shown in Table.2.

III. MACHINING DETAIL

A Madis-6 Computer Numerical Control turning machine
was employed to turning of work specimen at length of 40mm
under dry MQL and Nano lubricant setups. The single point
cutting tool insert were mounted on the ECLNL-2525M12
tool holder. New set of inserts and specimen are used in
turning operation. The photo image of machine setup is shown
Fig.1: The Schematic Diagram of Prepared (a) Work Material fig.3.
Sample and (b) Insert

Fig. 2: Experimental Setup Fig. 3: Machining with Arrangements

Table 1: Specification of Experiment IV. IDENTIFICATION OF MAIN FACTORS

Description Dimension The experimental work and evolving the mathematical
Optical Head MM200 model involving independent controllable process parameters
Monocular Optical Head or CMount
disturbing the tool wears are distinguished being cutting
Video Head for MM200
XYZ Stroke 50mm X 50mm X 110mm speed, feed rate and depth of cut. The responses investigated
Stage 2.5 + L/50 m (with LEC), 3 + L/50 m were the flank and crater wear.
Accuracy (L=Measurement Length in mm) A. Experimental Design Matrix
Scale 0.01/0.1(default)/1/10 m
Resolution The static analysis software is used for analysis the data.
Max. Loading 2 kg for Guaranteed Accuracy / 5 kg for Central composite design consisting of 20 set of coding
Weight Operation conditions
Magnification 0.1%
B. Developed Model
Accuracy
Objective Standard: 3x (75.5mm) Optional 1x The tool wear resistance based Dry MQL and Nano by
Lenses (W.D.) (79mm), 5x (64mm), 10x (48mm) machining operation under developed mathematical model.
Light Sources Standard: Diascopy/Episcopacy (White The responses are consequently expressed in the form of
LED), Optional: 8Segmented RSM1 equations as follows.
Flank wear
General structure of proposed model
= 0 + 1 + 2 + 3 + 11 2 + 22 f 2 + 33 2 + 12 +13 + 23 (1)

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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 6, No. 4, October 2016 143

Prediction of wear of proposed model

Flank wear
() = 1.0692 + 0.14 + 1.404 0.2081 2.2933 007 2 0.5333 2 + 0.5499 2 0.00014 + 0.0001
1.0416 (2)
Cranter wear General structure of proposed model
= 0 + 1 + 2 + 3 + 11 2 + 22 f 2 + 33 2 + 12 +13 + 23 (3)
Crater wear () = 1.3972 + 0.0016 + 0.9341 + 0.2913 0.0004 8.3333 005 + 0.3083 3.7422
007 2 0.1222 2 0.1222 2 (4)
C. Checking the Adequacy of the Developed Models variance in Flank wear is given in the Table.9 and error
The adequacies of the models (Eq.2 and Eq.4) were Analysis of variance in Crater wear
checked using the Analysis of Variance (ANOVA) technique. Flank wear
Analysis of variance Flank and Crater wear. Error Analysis of
General structure of proposed model
= 0 + 1 + 2 + 3 + 11 + 22 f + 33 2 + 12 13 + 23
2 2
(5)
Flank wear () = 1.32113 + 1.6608 003 + 0.84583 + 0.43361 1.50000 004 1.6667 004
0.23333 3.93778 007 2 0.19444 2 0.077778 2 (6)
= 0 + 1 + 2 + 3 (7)
Crater wear() = 0.60356 + 5011111 004 + 0.44444 + 0.16111 (8)
= 0 + 1 + 2 + 3 (9)
Flank wearGeneral structure of proposed model
= 0 + 1 + 2 + 3 + 11 2 + 22 f 2 + 33 2 + 12 +13 + 23 (10)
Prediction of wear of proposed model
Flank wear () = 0.14185 + 3.11111 005 + 0.083333 0.10278 + 1.66667 004 + 3.33333 005 +
0.16667 + 1.68889 007 2 + 0.13889 2 + 0.222222 (11)
Crater wearGeneral structure of proposed model
= 0 + 1 + 2 + 3 + 11 2 + 22 f 2 + 33 2 + 12 +13 + 23 (12)
2 2 2
= 0.54535 + 5.62889 004 0.99083 + 0.66194 + 4.96667 007 + 1.18889 0.81111 (13)

V. RESULT AND DISCUSSION

A. Direct Effect of Flank Wear
The direct effect of parameters were speed feed depth of
cut with different lubrication levels shown in fig.5.it reveals
that, there is increase in trend against flank and crater wear.
The carbide insert were treated and uncoated cutting
condition. The flank wear increased in increase in cutting
parameter to create a linear trend of different lubrication
condition. The percentage difference between the lubrication
conditions are 32.19%, 35.44%, 35.55% Dry, MQL and Nano
respectively
For crater wear increase in trend with linear curvature
parabolic curves are formed. From the initial speed the crater
wear ratio is same in 50 meter per minute. The percentage
difference between the different cooling conditions are
32.69%, 40.90% 95.63% with respect to Dry, MQL and Nano Fig. 4
respectively.

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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 6, No. 4, October 2016 144

Fig. 5: Direct Effect of Speed and Feed on Flank and Crater

Wear Fig. 7: Interaction Effect of Speed with Feed Rate in MQL
The speed increases and also increases the crater wear. The
Nano based lubricated turning process is the more wear
resistant followed by MQL and Dry turning process
B. Interaction Effects of Flank Wear
From fig.6-8, interaction effect of process parameter with
square term and interaction term absorbed from fig.6, feed rate
instead with degrees of flank wear parallel speed is increased
with increasing flank wear for MQL turning process. Flank
wear is decreased with increase of feed rate increase with
increase of speed as shown in fig.7. From fig.8 it reveals that
Nano lubrication based turning operation. The flank wear
increased with increased of speed and decrease with increase
of speed rate

Fig. 8: Interaction Effect of Speed with Feed Rate in NANO

C. Interaction Effects of Crater Wear
Figures 9-11 are plotted in X-axis and Y-axis is crater
wear with respect speed. Then speed is increases with
increases the flank wear. Then compare the three types of
coolant. MQL is low flank wear compare to the DRY. NANO
is low flank wear

Fig. 6: Interaction Effect of Speed with Feed Rate in Dry

Fig. 9: Interaction Effect of Speed with Feed Rate in Dry

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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 6, No. 4, October 2016
Fig. 10: Interaction Effect of Speed with Feed Rate in MQL
Fig. 11: Interaction Effect of Speed with Feed Rate NANO
VI. CONCLUSION
The tool wear analysis on different analysis on different
lubrication levels using single point cutting tool insert in
turning of AISI4340 steel and the following conclusions are
reached Flank wear and crater wear are the output responses.
The wear resistance between dry machining, minimum
quantity lubrication machining in the percentage of 19.04%,
17.69%and 8.22%. The experimental analysis of tool wear like
flank and crater of Al2O3 Nano material lubrication is the
dominant wear resistance to compare the other the others.
The RSM approach based on experimental is varied from
way to calculate the tool wear resistants. The optimized wear
resistance values are recommended industries in turning
operation.
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