Sustainable machining of hardened AISI630 stainless steel using thermally enhanced turning technique

Abstract The main objective of this study is to initially simulate the cutting process of hardened AISI630 stainless steel to implement thermally enhanced turning followed by hot turning (HT) experiments to demonstrate the effectiveness of the process and identify cutting parameters that would yield the optimum results in terms of sustainability. To precisely predict the chip morphology, as well as the cutting force and tool temperature, 2 D and 3 D FEM analysis, have been used, respectively using AdvantEdge software. The numerical analysis showed that HT in 300 °C causes a reduction of 28% in cutting forces. The tool wear in HT reduces up to 33% in comparison to conventional turning (CT). Furthermore, the relation between cutting force fluctuation and the machined surface roughness has been investigated applying numerical analysis and experimental data. The results revealed that HT in 300 °C reduces the machined surface roughness up to 23%. In addition, it has been observed that HT technique decreases side flow and surface damages in comparison to CT.