Minimizing tool wear in turning 42CrMo4 steel by comparing novel hard machining and flood cooling approaches with advanced inserts.

The goal of this study is to determine how to minimize tool wear (TW) when turning die steel with advanced novel inserts such as Cubic Boron Nitride (CBN) and Polycrystalline Diamond (PCD) under dry hard machining and flood cooling machining. Materials and methods: The material considered for investigation is 42CrMo4, with PCD and CBN as inserts. In this study, four groups are presumed: PCD with dry and flood cooling, CBN with dry and flood cooling, and the effectiveness of these inserts and cutting circumstances was compared. CBN inserts are used in the experimental group, while PCD inserts are used in the control group. Cutting speed, feed rate, and depth of cut are the cutting parameters used in this procedure. A total of 36 specimens were machined, considering 9 samples for each considered group based on G power calculator 80% with alpha value of 0.05. Result: The mean TW developed at the flank face of the cutting inserts for PCD insert under dry machining conditions is 1.1311 mm, and 0.7622 mm for flood cooling, whereas it is 0.93 mm and 0.6433 mm for CBN. In flood cooling conditions, the effectiveness of the CBN insert results in a lower TW. Among the considered groups significant variances exists; with a significance value of 0.000 between them when the statistical analysis (one-way ANOVA) is performed with 95% confidence interval. Conclusion: Within the scope of this study, the findings reveal that the TW is lower in flood cooling for both inserts than in dry machining, and that CBN outperforms PCD in flood cooling when evaluated to hard turning. [ABSTRACT FROM AUTHOR]