Machining performance evaluation of Ti6Al4V alloy with laser textured tools under MQL and nano-MQL environments

The study aims to conduct experimental investigations towards an integrated coolant and cutting tool based strategies for sustainable machining of Ti6Al4V alloy. Laser textured cutting tools were used under vegetable oil based MQL, and alumina suspended DI water based nMQL environments. The results were compared with plain and textured tools under dry condition with the same machining parameters. A detailed experimental plan was executed to conduct the series of experiments considering machining parameters, texture parameters and machining environment collectively. The MQL and nMQL parameters were selected based on spreadability of droplets at varying air pressure and flow rate. The results have shown a reduction in cutting forces, apparent friction coefficient, contact length, tool wear and chip adhesion over the rake face with textured tools under MQL environment. Nano fluid based cooling has a limited advantage over the range of cutting speeds and feeds as alumina nanoparticles get accumulated in the textured space. Reduced curling radius is obtained with textured tools due to the intense heat generated and associated interface multipoint micro-cutting (IMP-mu C) mechanism.