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Modern industry is probing for more incipient ways to ameliorate the sustainability of all the manufacturing processes. A homogeneous effort was made in this study for the drilling process sustainability amendment for aluminium 6061-T6 alloy. Minimum quantity lubrication (MQL) powered by a Ranque-Hilsch vortex tube (RHVT) was deployed as the base technique for cooling, made more efficacious by nano particle fluids (canola oil + MoS2). Comparisons were made amongst the RHVT air cooled drilling, RHVT powered MQL drilling and the nano particle availed RHVT powered MQL technique. The utilisation of synthetic non-biodergadable oils was plenarily eliminated. The experiments were designed utilising the RSM technique. The drilling speed (rpm) and the drill diameter (mm) were varied in three levels, whereas the feed was kept constant. Determinately, the optimisation was carried out by using the EA techniques; there the PSO, BFO and TLBO were compared followed by the conformation tests.

Hard turning is an attractive alternative to grinding for steel parts, which are often loaded to their physical limits. But in comparison to grinding, the issue of surface integrity in hard turning is not yet clearly established in context of its adaptability for industrial use. This paper presents a survey of recent research progress in regard of surface integrity issues related to hard turning of hardened steel. A significant pool of hard turning studies has been surveyed in an attempt to achieve better understanding of surface issues, i.e., surface roughness, residual stress, white layer formation and microhardness variations. Further important modelling techniques based on finite element, soft computing and other mathematical approaches used in hard turning are reviewed.

The experimental investigations of machining of Al-Si-Sic composite material at different cutting parameters are reported in this paper. This paper outlines an approach to quantify specific relationships between cutting variables and machining parameters. The models are formulated using response surfaces methodology. The experimental data points are observed to be best fitted by non-linear quadratic models. There are three cutting variables i.e., speed, feed and depth of cut and four machining parameters namely acoustic emission (AE), tool acceleration, surface roughness and flank wear. Perturbation plots are presented. The effect of various cutting variables on machining responses is analysed from these plots. Further regression model is tested and optimum cutting parameters are obtained.

The principal aim of this paper is to identify the wear mechanisms of CBN and mixed-ceramic tools during finish hard turning of low to medium hardness (42–52 HRC) AISI H11 steel under different machining conditions. The effect of machining parameters viz. cutting speed, feed rate, depth of cut and work hardness on wear pattern of these tools have been investigated. The prominent wear modes observed for CBN tool are abrasion wear, formation of transferred layer resulting from tribochemical reactions between constituents of tool, and workpiece material, built up edge, adhesion of workpiece material followed by plastic deformation and notching clearly visible at low workpiece hardness (47 HRC). The different wear mechanisms observed for mixed ceramic tool are abrasion wear, notch wear, chipping and brittle fractures of tool surface due to rubbing and impingement of hard particles in the work material, built up edge and adhesion followed by plastic deformation. The tool wear was characterised through optical microscopy and scanning electron microscope accompanied with energy dispersive analysis through X-ray.