Multivariate Optimization of Machining Forces Generated by End Milling of Hardox® 450 Steel Under Different Lubricooling Conditions

Hardox® is a martensitic steel characterized by high hardness and resistance to abrasive wear, increasingly used in the agricultural, mining, and transport industries. In some specific contexts, its application requires the fabrication of components through the machining processes. In addition, optimizing cutting parameters and correctly applying lubricooling techniques are essential to enhancing productivity while always seeking to reduce environmental damage. Thus, this work investigates the cutting parameters' effects on the active and passive forces and the static and dynamic portions of the machining force in the end milling of Hardox® 450 with PVD-TiAlN coated carbide inserts under different lubricooling conditions (dry, flood, and nanofluid-based reduced quantity lubrication "NF-RQL"), aiming to perform its multivariate optimization. As expected, the results showed that the depth of cut (ap) is the most significant parameter, followed by feed per tooth (fz) and the interaction between them. Although the force values obtained by lubricooling conditions were similar, NF-RQL can provide a higher material removal rate (1456 cm3/min) than dry (1116 cm3/min) and flood (1019 cm3/min) conditions. © 2023 School of Science, IHU. All rights reserved.