Title: Machinability investigation of S32750 super duplex stainless steel using magnetorheological fluid-assisted nano polished cemented carbide tool inserts

Authors: M. Thiyagu; J. Elanchezhian; G. Anbuchezhiyan; S.K. Narendranathan; Paneerselvam Purushothaman

Addresses: Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Science, Chennai-602105, Tamilnadu, India ' Department of Mechanical Engineering, Anand Institute of Higher Technology, Chennai-603 103, Tamilnadu, India ' Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Science, Chennai-602105, Tamilnadu, India ' Department of Aerospace Engineering, Agni College of Technology, Chennai, Tamilnadu, India ' Department of Mechanical Engineering, Agni College of Technology, Chennai, Tamilnadu, India

Abstract: This study investigates the nano polishing of cemented carbide tool insert surfaces using a magnetorheological fluid (MRF) assisted with diamond abrasives to improve tribological properties in the tool chip contact zone. The unique MRF assisted tool finishing process resulted in a tool insert surface roughness of less than 22.3 nm on the flank and less than 37.4 nm on the rake face. The machinability characteristics of the nano-finished inserts were investigated in the dry turning of S32750 super duplex stainless steel. Compared to unprocessed tools, MRF-assisted nano-finished tools demonstrated up to 30% longer tool life spans. The average tool life for the nano polished inserts was 27 min, compared to 19 min for the unprocessed inserts. Turning an S32750 super duplex stainless steel material resulted in an 18% reduction in cutting forces owing to the use of nano polished inserts, which also provided excellent lubricity. The results showed that nano polished inserts performed better than conventional inserts in terms of cutting force, flank wear, and surface roughness.

Keywords: tool texturing; magnetorheological fluid; MRF; diamond abrasives; surface roughness; cutting force; rake face; flank surface.

DOI: 10.1504/IJMMM.2024.141482

International Journal of Machining and Machinability of Materials, 2024 Vol.26 No.3, pp.244 - 266

Received: 13 Dec 2023
Accepted: 16 Mar 2024
Published online: 17 Sep 2024 *

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