Assessing the performance of ionic liquid-assisted minimum quantity lubrication during machining of biomedical-grade stainless steel with recently developed AlTiN/TiSiXN-coated carbide tool

Abstract

This research explores the cutting performance of newly developed DURANA (AlTiN/TiSiXN)-coated carbide tool and investigates the lubrication–cooling performance of ionic liquid-based lubricants for improving the machinability of biomedical-grade stainless steel under sustainable minimum quantity lubrication. This article also explores comparative performance assessment between two different ionic liquid-based lubricants (1-methyl 3-butylimidazolium tetra fluoroborate, BMIM BF4) and (1-methyl 3-butylimidazolium hexafluorophosphate, BMIM PF6). Technological performance characteristics such as cutting force and thrust force, flank and crater wear, surface integrity (surface roughness, surface morphology, residual stress, microhardness), chip morphology, and cutting temperature are taken into account when evaluating the machinability of biomedical-grade stainless steel. In addition, the study analyses the thermo-physical and tribological properties of ionic liquid (IL)-based lubricants for machining. The lubricant based on BMIM PF6 IL exhibited an improved wear resistance of coated tool, higher viscosity as well as thermal conductivity with minimal contact angle in comparison with the lubricant based on BMIM BF4. Due to the development of improved chip morphology, lower cutting forces and minimum cutting temperature, enhanced machined surface integrity, and decreased tool wear, the turning with BMIM PF6 IL-based lubricant committed superior than BMIM BF4-based lubricant.