Comprehensive review of advanced methods for improving the parameters of machining steels

The extensive range of steel types and classifications results in a diverse set of properties such as plasticity, heat resistance, strength, and corrosion resistance. This diversity enables the creation of alloys with varying machinability, from easy to hard-to-cut. This review focuses on the intricate interplay between mechanical characteristics of steel and machinability indicators such as tool wear, tool life, material removal rate (MRR), and chip formation. This review also highlights innovative strategies to enhance steel's machinability through the manipulation of cutting conditions. These approaches range from dry cutting to sophisticated cooling systems such as minimum quantity lubrication (MQL), cryogenic lubrication (CL), and high-pressure cooling (HPC). Additionally, the impact of tool design, including geometry and surface texturing, is scrutinized, along with the deployment of advanced tool materials and coatings. Furthermore, the paper investigates the efficacy of assisted machining techniques, including vibrational, thermal, and hybrid methods. A comprehensive review of advanced machining operations (encompassing turning, drilling, milling, and grinding) elucidates the potential improvements in surface integrity and machinability of steel. The review also addresses the challenges and future opportunities in this domain. In conclusion, the exploration into the machinability of steel underscores its significance as a versatile material in various industries. By understanding and optimizing the machining dynamics and employing innovative strategies, there is potential to further enhance the properties and machinability of steel alloys. This review provides valuable data compilation for researchers, engineers, and industry professionals seeking to advance the utilization of a large array of steel variants in manufacturing processes.