Effect of cutting parameters and high-pressure coolant on forces, surface roughness and tool life in turning AISI 1045 steel

The machining industries constantly look for novel techniques to decrease the forces generated in metal cutting, enhance the tool life and improve the surface quality. High-pressure coolant delivery is one such technique that is believed to enhance the overall machining process with its superior cooling capabilities. Hence, an investigation was made to compare the behavior of a turning tool in machining AISI 1045 steel material under conventional coolant (CC) and high-pressure coolant (HPC) conditions. The influence of applying coolant at high pressure on forces and surface finish was measured at various cutting speeds and feeds, and tool life analysis was performed at a constant cutting parameter. The study reveals that a 12-23% reduction in cutting force, a 17-27% reduction in feed force, and a 14-33% reduction in surface roughness values can be obtained when a high-pressure coolant is used. Besides, around 40% improvement in tool life was also seen. The capability of the coolant in the effective removal of heat from the tool-chip interface zone, decrease in frictional forces between the tool and work material, and superior chip breaking capabilities at high-pressure conditions are attributed to the performance improvement. (C) 2020 Elsevier Ltd. All rights reserved.