Enhancing the tribological aspects of machining operation by hybrid lubrication-assisted side-flank-face laser-textured milling insert

Abstract

The objective of this study was to find ways of improving the machining performance of steel considering sustainable development by limiting the application of hazardous lubricant. The textures having the most advantageous shape were employed with hybrid lubrication consisting of graphite powder in combination with the MQL having best suited tribo-rheological properties. The genetic algorithm code generated for optimization of the machining parameters was one of its kinds that could consider categorical factors along with the continuous factors for optimization. It was found that the optimum machining condition was the low depth of cut, textured flank face impregnated with graphite powder and boric acid-dissolved MQL. Waviness in shape and the rougher inner surfaces of the textures produced through laser beam machining were found to allow the insert to act as a self-lubricating insert satisfactorily throughout the machining operation. Reduction in surface roughness of 64.4% was observed with the proposed technique. Providing an extremely minimal amount of lubrication to the textured tool using the developed technique led to the improved machining performance through cleaner production aiming at omitting waste.