The International Journal of Advanced Manufacturing Technology (2021) 113:365–378

https://doi.org/10.1007/s00170-021-06672-9

ORIGINAL ARTICLE

Comparative assessment of lubri-cooling conditions when turning

CP-Ti Grade 4 based on surface roughness
Fabio Telles 1 & Heraldo J. Amorim 1 & André J. Souza 1

Received: 22 September 2020 / Accepted: 19 January 2021 / Published online: 24 January 2021
# The Author(s), under exclusive licence to Springer-Verlag London Ltd. part of Springer Nature 2021

Abstract
The unique combination of corrosion resistance, mechanical properties, and biocompatibility have made commercially pure
titanium (CP-Ti) widely used as bio-implant materials. The bio-implant requires high-quality surfaces, with specific character-
istics for each utilization. Due to high temperatures in the cutting zone and the high chemical affinity, titanium is usually
machined with cutting fluid. However, the environmental impacts drive research towards eliminating or reducing the utilization
of these fluids. Therefore, a Box-Behnken Design of experiments was used to investigate the effects of cutting parameters
(cutting speed, feed rate, and depth of cut) and lubri-cooling conditions (dry, MQL, RQL, and conventional flood) on the surface
roughness after turning CP-Ti (grade 4). Statistical analysis confirmed that the feed rate is the most significant cutting parameter
for controlling surface roughness, and it must be kept at a low level to improve the surface finish. The analysis of the results
indicates that each lubri-cooling atmosphere requires appropriate levels of cutting speed and depth of cut to enhance the
workpiece surface finish. The optimization of the experiment through the desirability function showed that RQL turning is the
best choice to minimize surface roughness on CP-Ti Grade 4.

Keywords Turning commercially pure titanium (grade 4) . Minimum quantity lubrication (MQL) . Reduced quantity lubrication
(RQL) . Box-Behnken Design . Surface roughness

1 Introduction Besides, the strain hardening during machining increases the

Titanium alloys are used to manufacture mechanical parts and
components for aerospace, automotive, oil, and biomedical
industries due to their excellent chemical and mechanical
properties, including high mechanical strength at high temper-
atures, low density, high corrosion resistance, and biocompat-
ibility. However, some of these characteristics contribute to
the low machinability of Ti alloys [1]. The high chemical
reactivity of this material favors adhesion, adding to tool wear,
which can lead to premature tool failure. The low thermal
conductivity of titanium increases the temperature in the cut-
ting zone, increasing tool wear and reducing the tool life. In
some cases, these high temperatures can lead to premature
failure through plastic deformation of the cutting edge.
* André J. Souza
ajsouza@ufrgs.br
1 ductility and moderate plasticity. CP-Ti Gr4 is used in applica-
Laboratory of Automation in Machining (LAUS), Department of
Mechanical Engineering (DEMEC), Federal University of Rio
Grande do Sul (UFRGS), Porto Alegre, RS, Brazil
cutting forces and heat generated, leading to rapid tool damage
[2].
Titanium has two basic crystalline structures: (i) compact
hexagonal (α-phase), characteristic of lower temperatures,
and (ii) centered body cubic (β-phase), which is an allotropic
transformation of the material that occurs at higher tempera-
tures. Due to these phases, Ti alloys are commonly classified
into four categories according to the crystalline structure and
alloying elements present, which act as phase stabilizers: α,
near-α, α + β, and β [3].
According to ASTM designation, commercially pure titani-
um (CP-Ti) is an α-alloy classified into four grades. These
grades diverge mainly according to the percentage of alloying
elements in its composition. Due to the low wt.% of these ele-
ments, CP-Ti has lower mechanical resistance and higher cor-
rosion resistance than other titanium alloys [4]. CP-Ti may also
be classified into four grades according to its properties. Among
CP-Ti, grade 4 offers the highest strength, allied with good
tions that require material resistant to corrosion and erosion,
especially when high mechanical strength is not required [5].
366
One of the main applications of CP-Ti is biomedical im-
plants, such as hip replacements. Since the success of these
implants relies on successful bone fixation, the quality of an
implant is directly related to the characteristics that favor the
growth of specific cells. Surface microtopography and rough-
ness of the implants affect cellular growth, which is also in-
fluenced by the manufacturing processes used to achieve the
surface texture [6]. On the other hand, the main concern for
the development of artificial heart valves is the formation of
blood clots, which can lead to thrombosis. In this case, the
surface roughness is an essential factor that can affect the
hemocompatibility of a biomaterial, and a smooth surface is
essential because rough surfaces may cause turbulence in the
blood flow, affecting the integrity of the red cells, which can
induce bacteria to adhere to the surface, blood coagulation and
clots [7].
Surface roughness refers to deviation from the nominal
surface characterized by micro geometric errors caused by a
set of irregularities such as small peaks and valleys that makes
a surface. Roughness is commonly used as an output variable
to control a machining process in many cases, and several
parameters influence this deviation. The most used parameter
to assess surface roughness in the industry is the average
roughness (Ra). However, this parameter is weakly influenced
by random effects and should not be considered in isolation.
Therefore, the Rz parameter (mean peak-to-valley heights of
five adjoining sampling lengths) can complement the analysis
since this parameter is more sensitive to occasional high peaks
or deep valleys than Ra, providing a better sense of deviations
from the mean [8, 9].
Usually, the reduction of surface roughness in the machin-
ing of titanium alloy is a topic of interest. Factors like built-up
edge (BUE) formation, tool geometry, tool coating, tool wear,
cutting temperatures, feed rate, cutting speed, and depth of cut
affect the finishing of titanium surfaces. These effects are
mainly present due to mechanical and thermal stresses, micro-
structural transformations, and mechanical and thermal defor-
mations occurring during machining processes [10]. Although
titanium alloys are generally susceptible to BUE, pure metals
(like CP-Ti) typically do not form large BUE even at low
cutting speeds [11].
Since titanium is a difficult-to-machining material, proper
planning of the manufacturing process becomes essential to
ensure quality and involve the cutting tool selection. Coated
carbide inserts with a hard ultra-fine-grained substrate are in-
dicated for machining stainless steels, heat-resistant superal-
loys (HRSA), and Ti alloys requiring high resistance to
microchipping and high hot hardness [12].
Titanium machining generates very high temperatures due
to its high hot hardness and its high mechanical strength.
Moreover, due to its low thermal conductivity, the generated
heat cannot be dissipated appropriately from the cutting zone,
becoming concentrated and contributing to premature tool
Int J Adv Manuf Technol (2021) 113:365–378
failure [13]. Flood application of cutting fluids is the most
usual method to provide cooling, lubrication, and chip remov-
al [14]. However, the use of cutting fluids in machining oper-
ations has become an inconvenience due to the environmental,
economic, and occupational health issues associated [15].
Thus, several techniques here referred to as lubri-cooling con-
ditions (LCC) have been studied to provide an environmen-
tally conscious perspective in titanium machining, including
dry cutting and minimum quantity lubrication (MQL).
Dry cutting is the greenest solution since it eliminates the
use of cutting fluid. Its advantages are the reduction of ma-
chining costs associated with the acquisition and disposal of
cutting fluids, the absence of environmental pollution, no con-
tamination of chips, and no danger to the operators’ health.
Additionally, increasing environmental and occupational con-
cerns reinforced by current standards (e.g., ISO 14000 and
OHSAS 18000) instigate the complete elimination of cutting
fluids from the machining processes. However, dry cutting
results in higher heat generation and generally leads to shorter
tool lives, thus demanding more expensive cutting tools with
specific characteristics to work within this condition [16]. The
high chemical reactivity of titanium, especially at high tem-
peratures, leads to localized adhesion in the tool-workpiece
interface, resulting in increased tool wear, tool chipping, and
occasionally tool failure [17]. Furthermore, dry cutting is un-
able to provide adequate surface finish in many situations.
Also, the necessity to avoid excessive heat generation limits
the use of high cutting speeds [15].
Since the problems associated with dry and flood machin-
ing, alternatives were created to combine the advantages of
both methods. These techniques, which are based on smaller
quantities of cutting fluid, were developed as greener alterna-
tives to conventional flood cooling. The literature presents
diverse terminologies for the methods based on small amounts
of lubrication depending on the flow rate.
NDM (near-dry machining) refers to the use of flow rates
smaller than 0.05 l/h, while MQL (minimal quantity of lubri-
cant) assumes flow rates from 0.05 to 0.5 l/h. Since flood
conditions operate at flow rates above 300 l/h, there is a wide
flow range between MQL and flood conditions (0.5–300 l/h)
that is rarely used. Thus, the reduced quantity lubricant (RQL)
could be used similarly to MQL, but with a higher amount of
fluid, since RQL generally involves flow rates from 0.5 to 10
l/h [18]. In MQL, a small amount of lubricant is atomized and
delivered to the cutting zone with compressed air, forming a
lubricant mist. The success of this method requires an analysis
of the whole system. Ideally, its application starts from the part
design and considers rightly machine and cutting tools, chip
management, and cutting fluid supply system [19]. Machining
performance using RQL or MQL is affected by the lubricant
type, flow rate, distance between the nozzle and tool nose,
workpiece material, and cutting conditions. Only adequated
lubricant quantity and nozzle positioning provide suitable
Int J Adv Manuf Technol (2021) 113:365–378
process conditions. Therefore, the correct type of lubricant
should be considered [20, 21].
Conventional flood application of LCC is not suitable for
machining aerospace alloys (e.g., titanium) since the forma-
tion of a vapor blanket caused by the sublimation of the fluid
components at high temperatures prevents the cutting fluid
access to the tool-chip and tool-workpiece interfaces [2].
Furthermore, several studies indicate the better efficiency of
MQL than dry and flood machining of titanium due to better
lubrication ability. This method applies small quantities of
lubricant (eliminating the vapor blanket) in the form of a mist,
which can reach difficulties in accessing the surfaces. Several
results connect the reduction of the friction in tool-workpiece
and tool-chip interfaces with the reduction of the tool wear and
a decrease of the machining temperature [13–15, 22, 23].
Optimization of the machining parameters is an essential
tool to ensure the functional characteristics with the desired
quality and high productivity [24]. Response surface method-
ology (RSM) is a collection of mathematical and statistical
techniques useful for modeling and analyzing problems in
which several variables influence the response of interest,
and the objective is to optimize this response. This methodol-
ogy also quantifies the relationship between the controllable
factors (input parameters) and the obtained response surfaces
[25].
Considering the technical hindrances related to titanium
machining and the hazardous implications of conventional
flood machining, this work aims to evaluate the surface finish
generated by turning CP-Ti Grade 4. Three levels of each
cutting parameter (cutting speed “vc,” feed rate “f,” and depth
of cut “ap”) are tested in four lubri-cooling techniques (dry,
MQL, RQL, and flood machining) to verify its effectiveness
in minimizing surface roughness (Ra and Rz values) after the
cutting process.
The machining of CP-Ti Grade 4 has been poorly docu-
mented. Thus, the main novelties of this work are mapping the
relationship between surface finish, lubri-cooling conditions,
and machining parameters for turning with ultra-fine grained
carbide tools. Moreover, the presented results indicated that
multiple combinations of parameters might lead to similar
results. These combinations may be selected to aim the desired
characteristics of the machined parts and secondary goals such
as dimensional accuracy, productivity, low cost, renewability,
and tool life through literature analysis.
2 Materials and methods
Cylindrical workpieces of CP-Ti Grade 4 were processed with
different combinations of machining parameters in a Mazak
Quick Turn Nexus 100-II CNC lathe with a power of 23.5
kVA and a maximum spindle speed of 6000 rpm.
Workpieces with an original diameter of 22.3 mm and
367
95 mm in length were positioned using a three-jaw chuck
and machined with different cutting conditions. Three 12-
mm long sections were made in each part before the tests to
accommodate each evaluated condition. Table 1 presents the
material composition (%wt.), measured with a BRUKER Q2
ION spark emission spectrometer.
All samples were machined with TNMG 160404 SF 1105
ISO-S cemented carbide inserts manufactured by Sandvik
Coromant. ISO-S tools are suitable for machining HRSA
and Ti alloys. These inserts have a 0.4-mm tool-nose radius
and a PVD-TiAlN coating with excellent adhesion on a
submicron-grained (< 1.0 μm) substrate with 6% Co, resulting
in high hot hardness and good resistance against plastic defor-
mation and flank wear. According to the manufacturer, the SF
geometry is recommended for chip breaking in finish and
semi-finish turning of titanium. The selected inserts were sup-
ported by a Sandvik Coromant DTJNL 2020 K16 tool holder,
with negatives lead angle (− 3°), side, and back rake angles (−
6°). Since all tests were performed in finishing conditions,
each cutting tool edge was used to execute only three passes
(runs) to restraint the influence of tool wear over the surface
finish of the machined parts.
Figure 1 a presents the experimental setup used. The tests
were performed under four lubri-cooling conditions (LCC):
dry, MQL, RQL, and flood machining. For the MQL and
RQL tests, Quimatic Jet (by Quimatic®/ Tapmatic®), a
water-based synthetic cutting fluid, was applied by a
Quimatic IV nebulizer with an air pressure of 4 bar. The noz-
zle was positioned at a 40-mm distance from the cutting zone,
with a 90° inclination from the tool reference plane (Fig. 1b).
MQL machining was performed with a 400-ml/h flow rate,
based on tests performed by Gupta et al. [26] that obtained
lower values of surface roughness in MQL turning of CP-Ti
with flow rates equal to or greater than 300 ml/h. According to
Garcia et al. [18], RQL can be used similarly to MQL but
considering a flow rate between 0.5 and 10 l/h. In this study
(turning AA 6082-T6), a 2.0-l/h flow rate was adopted. The
approximate cutting fluid flow of the CNC lathe used is 640
l/h. For this LCC, the BD-Fluid B90® bio-lubricating fluid
was used, which is oil-free (it does not generate toxic vapors),
biodegradable, and developed with raw materials from renew-
able sources by Bondmann Chemistry Co. Dry machining
tests were performed without any LCC.
The response variables (Ra and Rz) were measured with a
Mitutoyo SJ-201P stylus profilometer, with a resolution of
0.01 μm. A 0.8-mm sampling length was used with a standard
Table 1 Chemical composition of CP-Ti Grade 4 (%wt.)
Ti Fe O C N Al Cu Others
99.45 0.399 < 0.05 0.014 < 0.05 0.008 0.011 < 0.06
368 Int J Adv Manuf Technol (2021) 113:365–378

(a) (b) (c)

Fig. 1 a Experimental setup. b Position of MQL/RQL nozzle. c Surface roughness measurement

evaluation length of 4 mm, according to DIN EN ISO 4288
(0.1 < Ra ≤ 2.0 μm and 0.5 < Rz ≤ 10 μm). The surface
roughness measurement was performed without removing
the workpiece from the CNC lathe, as shown in Fig. 1c. For
each run, three equidistant measurements were made around
the workpiece.
The chosen input controllable factors were cutting speed
(vc), feed rate ( f ), depth of cut (ap), and lubri-cooling condi-
tion (LCC). The cutting parameters (vc, f, ap) were established
as continuous variables and evaluated at three levels, selected
within the range of values recommended by the tool manufac-
turer. The LCC was defined as a categorical variable and eval-
uated in four levels. Preliminary tests were carried out to ver-
ify the suitability of the selected input variables. In these tests,
the titanium turning with the highest cutting speed suggested
by the manufacturer (80 m/min) resulted in negligible tool
wear after a relatively large machining length (about 600
mm). Thus, it was decided to extrapolate up the vc values to
verify its possible influence on the surface finish in a short
machining length (samples of 12-mm length).
The experiment was combined and randomized using
Box-Behnken Design (BBD), with one run for each com-
bination and three runs for the central point, totaling 15
runs for each LCC [18] (i.e., 60 runs), as presented in
Table 2. However, due to the difficulty in adjusting the
MQL and RQL flow rates, the 15 runs for each lubri-
cooling atmosphere were made separately. Consequently,
the LCC was not randomized. Even so, the lack of ran-
domization of the lubri-cooling techniques is unlikely to
influence statistical results. The main reason for using

Table 2 Experimental design

with average values of Ra and Rz Run Cutting parameters Response variables
for all machining conditions
Dry MQL RQL Flood

vc f (mm/ ap Ra Rz Ra Rz Ra Rz Ra Rz
(m/min) rev) (mm) (μm) (μm) (μm) (μm) (μm) (μm) (μm) (μm)

1 80 0.08 0.35 0.58 2.87 1.32 6.43 0.50 2.52 0.58 2.63
2 240 0.22 0.35 3.80 15.73 3.90 14.98 4.27 16.32 4.07 14.82
3 160 0.15 0.35 1.54 7.29 1.88 7.59 1.41 6.13 1.77 7.38
4 240 0.15 0.50 1.70 7.42 1.42 6.44 2.08 8.23 1.75 7.17
5 160 0.15 0.35 1.58 7.03 1.40 5.97 1.83 7.36 1.66 6.36
6 80 0.22 0.35 3.95 14.62 3.57 13.73 3.89 15.31 3.55 14.68
7 160 0.15 0.35 1.68 6.83 1.83 7.54 1.96 7.58 1.61 6.71
8 240 0.08 0.35 0.49 2.64 0.69 3.28 0.54 2.99 0.56 3.40
9 160 0.22 0.20 3.68 14.54 4.64 17.25 4.08 15.70 3.22 12.77
10 80 0.15 0.50 1.88 7.73 2.06 7.77 1.74 7.88 2.05 8.27
11 160 0.08 0.50 0.64 3.40 0.62 3.76 0.69 3.20 0.61 2.81
12 80 0.15 0.20 1.92 7.64 1.85 6.47 1.35 6.24 1.56 7.21
13 160 0.08 0.20 0.47 2.67 0.71 3.06 0.46 2.51 0.55 2.49
14 240 0.15 0.20 1.72 7.29 2.16 8.28 2.17 7.90 1.57 6.53
15 160 0.22 0.50 3.90 16.03 4.32 16.56 4.23 17.07 3.54 14.27
Int J Adv Manuf Technol (2021) 113:365–378 369

BBD was the small number of runs necessary compared
with other types of experimental designs (DOE) for sim-
ilar information and the characteristic avoidance of ex-
treme conditions in this DOE since this method does not
allow combinations of all factors in their highest or lowest
levels.
Statistical analysis was performed with the Minitab™17.
Analysis of variance (ANOVA) with a 95% confidence
level was used to verify each input parameter's influence
on the surface roughness. Coefficients of determination
were presented, and the experimental and predicted values
were compared to each other by regression equation plots.
Response surface and contour plots showed the varying
influence of the input parameters on the roughness values.
RSM was used to determine the best levels of the cutting
parameters and the proper lubri-cooling condition that min-
imize surface roughness. Finally, three passes were execut-
ed with the optimized parameters to validate the optimiza-
tion results.
3 Results and discussions
3.1 Statistical analysis
The average values of the measured response variables (Ra
and Rz) for the four lubri-cooling methods (dry, MQL, RQL,
and flood) are presented in Table 2 for each cutting condition.
In absolute values, the lower levels of surface roughness were
obtained with RQL, followed by dry, flood, and MQL ma-
chining. MQL also provided the highest roughness values of
all LCC.
Table 3 shows the analysis of variance (ANOVA),
standard deviation (s), and determination coefficients
(R2). For a 95% confidence level, a factor is statistically
significant if p value ≤ 0.05. Moreover, considering fur-
ther analysis in this work, a factor is considered “almost
significant” if 0.05 < p value ≤ 0.06, i.e., a confidence
level between 94 and 95%. According to the ANOVA,
feed rate ( f ) presented a statistically significant influence
on Ra and Rz values, contributing to about 96% of the
surface roughness response. The main effect of LCC is
also significant for Ra (about 0.6% influence). Some ef-
fects have almost significant statistical influence. For Ra,
these effects are related to the interactions that involve vc
with other input variables (f, ap, LCC). For Rz, the main
effect of ap is also almost significant.
The values of the coefficients of determination (R-square)
showed in Table 3 indicate that the model is well fitted to the
data. Equations (1) to (4) present the regression equations
from statistical analysis for Ra in the different LCC and Eqs.
(5) to (8) for Rz.
RaDry ¼ 1:162−0:00396 vc −11:78 f −0:45 ap
þ 0:00001 vc 2 þ 106:9 f 2 þ 3:07 ap 2
þ 0:02001 vc * f −0:00898 vc *ap þ 0:02 f *ap ð1Þ

Table 3 ANOVA of Ra and Rz

for finish turning of CP-Ti Grade Ra Rz
4
Factor DF SS MS F p value SS MS F p value

vc 1 0.01 0.01 0.20 0.661 0.06 0.06 0.09 0.763

f 1 86.49 86.49 1749.00 < 0.001 1172.73 1172.73 1689.80 < 0.001
ap 1 0.04 0.04 0.76 0.390 2.79 2.79 4.02 0.052
LCC 3 0.56 0.19 3.80 0.018 5.11 1.70 2.46 0.078
vc × vc 1 0.06 0.06 1.18 0.283 0.46 0.46 0.66 0.422
f×f 1 4.05 4.05 81.95 < 0.001 60.71 60.71 87.48 < 0.001
ap × ap 1 0.07 0.07 1.42 0.240 0.91 0.91 1.31 0.260
vc × f 1 0.20 0.20 4.06 0.051 1.98 1.98 2.86 0.099
vc × ap 1 0.18 0.18 3.75 0.060 1.46 1.46 2.11 0.155
vc × LCC 3 0.40 0.13 2.72 0.058 1.81 0.60 0.87 0.466
f × ap 1 < 0.01 < 0.01 < 0.01 0.997 0.10 0.10 0.14 0.710
f × LCC 3 0.30 0.10 2.04 0.124 4.97 1.66 2.39 0.084
ap × LCC 3 0.28 0.09 1.87 0.151 1.56 0.52 0.75 0.530
Lack-of-fit 30 1.55 0.05 1.26 0.388 22.81 0.76 1.71 0.218
Pure error 8 0.33 0.04 3.56 0.45
Total 59 94.42 1279.79
s = 0.2224 R2 = 0.9801 s = 0.8331 R2 = 0.9794
370
RaM QL ¼ 1:745−0:00399 vc −11:90 f −1:50 ap
þ 0:00001 vc 2 þ 106:9 f 2 þ 3:07 ap 2
þ 0:02001 vc * f −0:00898 vc *ap þ 0:02 f *ap ð2Þ
RaRQL ¼ 0:324−0:00054 vc −9:78 f −0:15 ap
þ 0:00001 vc 2 þ 106:9 f 2 þ 3:07 ap 2
þ 0:02001 vc * f −0:00898 vc *ap þ 0:02 f *ap ð3Þ
Ra Flood ¼ 0:980−0:00268 vc −13:71 f þ 0:15 ap
þ 0:00001 vc 2 þ 106:9 f 2 þ 3:07 ap 2
þ 0:02001 vc *f −0:00898 vc *ap þ 0:02 f *ap ð4Þ
RzDry ¼ 4:81−0:0091 vc −48:7 f −2:76 ap þ 0:000028 vc 2
þ 413:8 f 2 þ 11:01 ap 2
þ 0:0629 vc *f −0:0252 vc *ap þ 7:4 f *ap ð5Þ
RzM QL ¼ 7:34−0:0116 vc −54:7 f −5:23 ap
þ 0:000028 vc 2 þ 413:8 f 2 þ 11:01 ap 2
þ 0:0629 vc * f −0:0252 vc *ap þ 7:4 f *ap ð6Þ
RzRQL ¼ 2:71−0:0040 vc −41:8 f −1:43 ap
þ 0:000028 vc 2 þ 413:8 f 2 þ 11:01 ap 2
þ 0:0629 vc * f −0:0252 vc *ap þ 7:4 f *ap ð7Þ
Rz Flood ¼ 5:46−0:0108 vc −56:1 f −1:87 ap
þ 0:000028 vc 2 þ 413:8 f 2 þ 11:01 ap 2
þ 0:0629 vc * f −0:0252 vc *ap þ 7:4 f *ap ð8Þ
Figure 2 compares the experimental data with those
predicted by the statistical model in different lubri-
cooling atmospheres. These plots confirm the fit of the
model to the empirical data.
Int J Adv Manuf Technol (2021) 113:365–378
Figure 3 shows representative response surface plots
for Ra and Rz behaviors relative to the input variables.
For each plot, two variables were analyzed together,
while the third variable was kept constant at the medium
level (center point) of the experimental design. For all
lubri-cooling techniques tested, the surface roughness re-
sponse had similar behavior with the levels of cutting
parameters, which resulted in a resemblance at the re-
sponse surface plots for any LCC. The feed rate ( f ) is
the parameter that most affects surface roughness, as
ANOVA showed. Therefore, the higher the feed rate,
the greater the machined surface roughness, with a very
significant quadratic effect as expected (even using feed
rates smaller than the tool-nose radius, the height of the
peaks and the depth of the valleys tend to increase in a
quadratic proportion to the feed rate during the turning
operation [9]). This effect can also be verified in
Table 2, where the highest Ra and Rz values were gen-
erated in runs 2, 6, 9, and 15, in which the highest value
of f was used (0.22 mm/rev).
Also, the lowest values of the measured roughness oc-
curred when runs 1, 8, 11, and 13 were performed, which
was expected due to the lowest feed rate (0.08 mm/rev) used
in these runs. The exception was in run 1 with MQL, whose
surface roughness value was significantly above the others,
probably due to the contact between the snarled chip and the
workpiece. Thus, as expected, low levels of feed rate are es-
sential in the finish turning of CP-Ti Grade 4.
Main effects and response surface plots do not show
significant influence from the other cutting parameters on
the response because, as expected, the feed rate ( f ) has a
strong influence on surface roughness (about 96%), as
evidenced by the statistical analysis. Therefore, varia-
tions on cutting speed (vc) and depth of cut (ap) did
not present significant influence over surface roughness
for the tested conditions. Nevertheless, since the interac-
tion between vc and other controllable factors is almost-
significant for Ra, and ap also has an almost-significant
statistical influence for Rz, the effect of these parameters
cannot be entirely neglected. Their influence is most vis-
ible in a narrow range of surface roughness values.
The ANOVA indicates a significant influence of the
evaluated LCC for the average roughness Ra. Figure 4
presents contour plots of vc × ap for dry, MQL, RQL,
and flood machining, respectively. In these plots, the
system response is modeled in a two-dimensional surface
(area), in which specific ranges of response values are
delimited through contour lines with different shades of
gray. For each represented condition, f was set at a low
level (0.08 mm/rev) because this level allows the best
surface finish, as previously related. In this case, the
lighter shades on the contour plots illustrate the lowest
surface roughness values, i.e., the best results.
Int J Adv Manuf Technol (2021) 113:365–378
Fig. 2 Experimental and (a)
predicted values of surface
roughness when turning with
different lubri-cooling conditions:
a Dry, b MQL, c RQL, d Flood
(b)
(c)
(d)
The analysis of Fig. 4 shows that dry and MQL machining
presented similar behaviors. Both LCCs result in lower sur-
face roughness when machining with high cutting speeds and
medium to high cutting depths. The reduction of Ra and Rz
values with the increase of vc is probably associated with the
material softening due to the higher temperatures generated,
reducing cutting forces and chip deformation on the tool nose,
improving the surface finish [27]. Moreover, the increase of ap
can also increase chip temperature, leading to its softening and
reducing frictional forces, thereby contributing to a better sur-
face finish [28].
Despite the lubrication provided by the MQL, there is no
significant difference in the levels of the cutting parameters
that reduce the roughness values compared with dry
371
machining. However, the ap from which average roughness
Ra begins to improve in dry cutting is lower than those ob-
served in MQL, and for dry machining, Rz tends to increase
over again for higher ap. A possible reason for this behavior is
that the lubrication provided by MQL, while not sufficient to
surmount the strain hardening of the workpiece material,
might still contribute to reducing the temperature in the cutting
zone, thus allowing the adoption of higher cutting parameters.
Thus, higher ap and vc would be required to soften the work-
piece material, improving both productivity and the surface
finish. Nevertheless, an increase in vc and ap in both lubri-
cooling techniques reduces the surface roughness values.
The analysis of Fig. 4 shows that RQL machining requires
low levels of vc and ap to allow smaller roughness. The
372
Fig. 3 Representative response Ra
surface plots of Ra and Rz
RQL
vc = 160 m/min
Dry
ap = 0.35 mm
Flood
f = 0.15 mm/rev.
improvement of surface finish, using low levels of cutting
parameters, was also observed in dry and flood machining.
These results were attributed to minor wear, stresses, and ad-
hesion of the workpiece material on the tool, as well as less
friction at the chip-tool interface [29–32]. The literature shows
that vc and ap levels are usually different for better surface
quality when MQL or RQL machining. While one of them
must be set at a low level, the other must be at a medium or
high level, and vice-versa. When considering the cutting pa-
rameters separately, studies report that the decrease of the
material removal rate, either by the decrease of vc, f, or both,
tends to decrease the surface roughness [30, 33]. Besides, high
temperatures (associated with higher material removal rates)
lead to higher Ra and Rz values in turning titanium due to
increased tool wear and adhesion of material in the cutting
Int J Adv Manuf Technol (2021) 113:365–378
Rz
MQL
Flood
RQL
tool [30, 33]. RQL machining results agree with the literature
when the depth of cut is considered: smaller ap tends to de-
crease Ra and Rz, likely due to the lower thermal load and
vibration generated on the machine tool [31, 34–36]. Another
possibility is that the RQL machining was more effective at
the low levels of cutting parameters, reducing the friction due
to the better lubricity in the machining interface, favoring the
chip flow, and improving the surface quality. According to
Rahim and Dorairaju [21], a higher lubricant flow rate on
RQL with input air pressure has enhanced heat dissipation
efficiency, improved the lubricating effect, and reduced the
friction when compared to MQL.
Low Ra values can be obtained with a wide range of cutting
speeds, from lower levels of depth of cut (ap) for any cutting
speed (vc) to higher levels of ap for higher vc when flood
Int J Adv Manuf Technol (2021) 113:365–378
Ra
Dry
MQL
RQL
Flood
Fig. 4 Contour plots of vc × ap for machining with different lubri-cooling conditions (f = 0.08 mm/rev)
machining (Fig. 4). For Rz, the vc range that provides the best
finish comprises a medium to a high level. Therefore, consid-
ering both Ra and Rz, a better finish is achieved with medium
or high levels of vc and low or intermediate levels of ap. As
previously related, the increase in temperature generated in
titanium turning due to higher vc can contribute to the mate-
rial’s softening, potentially improving the surface finish [27,
373
Rz
34]. In contrast, flood coolant provides more significant re-
frigeration and thermal stability of CP-Ti Grade 4 workpiece
than MQL [9]. It is then estimated that a higher cutting speed
is necessary to facilitate the material softening and improves
surface quality. There is a considerable variation in ap levels
that minimize the surface roughness; however, only the
highest ap was deleterious for the surface roughness under
374
tested conditions. As aforementioned, lower ap reduces vibra-
tions on the machine tool, thus preserving the workpiece sur-
face quality [31, 34–36]. For intermediate levels of ap, flood
LCC allows some lubrication, allowing chip flow without sur-
face finish deterioration.
3.2 Surface roughness profiles
Statistical analysis shows that the feed rate ( f ) is the most
influential parameter for all lubri-cooling methods. The
smallest surface roughness values were observed in runs 1,
8, 11, and 13 (all with the lower f). The only condition that
generated a higher roughness value at a low f was run 1 for
MQL. Similarly, the highest surface roughness values oc-
curred in runs 2, 6, 9, and 15 for all LCC, all with the higher
f tested.
Figure 5 shows examples of measured roughness profiles
that presented similar behavior for all LCC. The profiles clear-
ly show the influence of the feed rate on the response vari-
ables. The distance between two sequential peaks corresponds
to the approximate value of f for each condition. Therefore, as
aforesaid, for a given tool-nose radius (in this case rε = 0.4
mm), the height of peaks and depth of valleys of the feed
marks tend to increase in quadratic proportion to f [9].
The roughness profile presented in Fig. 5a shows some
discontinuities, while in Fig. 5b, these are very regular (pos-
sibly because of some tool failure or material adhesion). A
probable cause for these discontinuities is the presence of
scratches or marks (Fig. 6a and b) due to contact of the snarled
chip with the machined surface, observed in most of the tested
conditions (Fig. 6c).
3.3 Multivariate optimization
The response surface optimization aims to find optimal values
of cutting parameters to minimize Ra and Rz simultaneously.
Both Table 4 and Fig. 7 show the results of the multivariate
optimization obtained from Minitab™. The optimal values of
the cutting parameters and the LCC that tend to minimize the
roughness values, the desirability functions, and the predicted
(a)
Fig. 5 Examples of surface roughness profiles obtained in RQL condition: a Run 1 (f = 0.08 mm/rev); b Run 15 (f = 0.22 mm/rev)
Int J Adv Manuf Technol (2021) 113:365–378
responses (y) for Ra and Rz are presented according to the
model.
Based on the experimental data and the statistical-
mathematical model achieved, the software optimization rou-
tine scans the data to achieve a specific objective, which in the
case of this study is the minimization of surface roughness
values. In the desirability function approach, the measured
values of each predicted response are transformed into a de-
sirability value (d) that are then aggregated into a composite
desirability function (D). The scale of the desirability function
ranges between d = 0, which suggests a response completely
unacceptable, and d = 1, which suggests a response that is
exactly the target value. The value of d increases with the
desirability of the corresponding response [24, 37].
The multivariate optimization through the desirability
function pointed out that RQL is the best choice among
the lubri-cooling atmospheres to provide the best surface
finish after CP-Ti Grade 4 turning. As seen in Table 2, the
lowest absolute values of surface roughness were obtained
with RQL machining. For this condition, all cutting param-
eters (f, vc, and ap) must be kept at a low level to improve
the workpiece surface finish, as shown in the contour plots
of Fig. 4 and the optimization. The feed rate is the param-
eter that causes the highest effect on the response because,
as expected, a small increase in f causes a substantial
growth in the surface roughness values. Therefore, it is
essential to keep f at the lowest level to ensure the best
surface finish. Lower vc and ap would decrease the tool’s
material load, reducing its thermal load and vibration on
the machine tool. Moreover, a small ap (especially when
combined with a small f) results in low friction due to the
smaller contact area at the chip-tool interface [31, 34–36].
Besides, the lubrication effect of RQL would facilitate the
chip flow, which improves surface quality.
Three runs were performed with the optimized parameters
to validate the model and the expected responses (Table 4).
Table 5 presents a comparison between the average Ra and Rz
from the validation tests and those predicted by the optimiza-
tion functions.
The results of the validation tests did not reach the
responses predicted by the experiment optimization.
(b)
Int J Adv Manuf Technol (2021) 113:365–378
(a)
Fig. 6 Possible cause of discontinuities in the surface roughness profile: a marks on the machined surface; b mark detail; c chip rolled over the workpiece
However, the roughness values achieved in the optimiza-
tion validation (0.46 and 2.63 μm) were smaller than the
best results found during the 15 initial experimental runs.
Ra and Rz values predicted through second-order models
tend to be generally lower than the real (validated) values.
According to Benardos and Vosniakos [38], these real
values depend on the nature of the surface roughness for-
mation mechanism along with the numerous uncontrolla-
ble factors that influence the cutting phenomena (cutting
force variation, friction in the cutting zone, chip forma-
tion, vibrations, thermal conditions, and deflection of the
cutting tool). This argument reinforces the validity of the
statistical model, thus validating the optimized cutting
parameters.
Considering this study, RQL is considered the best
choice for the finish turning of CP-Ti Grade 4 in the most
tested conditions, providing the lowest surface roughness
values. Also, RQL is an environmentally friendly strategy
in turning compared to flood coolant. Thus, RQL machin-
ing is a viable alternative to replace flood machining and
minimize the economic, environmental, and social prob-
lems associated with the use of cutting fluids. However,
some important machining variables were not part of this
study’s scope, such as machining forces and tool life.
Fortunately, these variables may be approached through
literature analysis and cross-referenced with the results of
this study, thus allowing the combination of satisfactory
results since different combinations of the studied param-
eters may lead to similar results, even with different
LCCs.
Table 4 Results of experiment optimization
Optimized parameters Predicted responses (y)
vc (m/min) f (mm/rev) ap (mm) LCC Ra (μm)
80 0.08 0.20 RQL 0.3231
375
(b) (c)
4 Conclusions
This work evaluated the influence of the machining parame-
ters and lubri-cooling techniques over the surface roughness
of CP-Ti Grade 4 turning. According to the results, it was
possible to point some conclusions:
& As predicted in the literature, the feed rate ( f ) is the most
influential parameter over average roughness (Ra) and av-
erage maximum profile height (Rz) in turning of CP-Ti
Grade 4. The higher the feed rate, the greater the measured
roughness values. Thus, f must be kept at low levels to
provide a better surface finish.
& Both surface roughness parameters evaluated (Ra and Rz)
presented different behaviors for different lubri-cooling
conditions (LCC). Then, the definition of the process pa-
rameters for small roughness must consider the chosen
LCC. Thus, each LCC requires specific machining param-
eters to improve the workpiece surface finish.
& Both dry and MQL machining require higher cutting
speed (vc) and depth of cut (ap) to minimize the surface
roughness, probably due to the material softening associ-
ated with the high temperatures developed in these
conditions.
& There is a wide range of cutting parameters that produces a
better surface finish with flood machining. Low Ra values
were obtained at any level of vc tested, depending on the
depth of cut. When medium ap is used, higher cutting
speeds are necessary to provide better surface quality.
However, it is only possible to reach low Rz values with
medium or high cutting speeds. For the conditions tested,
the only level of ap that harms the surface roughness is the
highest. Conventional flood coolant is the most versatile
LCC among the tested conditions because several combi-
nations of cutting parameters can be used to achieve a
better surface quality.
Rz (μm)
& The best surface finish (lowest roughness values) was
2.1468 achieved with low levels of all machining parameters in
RQL turning. Therefore, it is assumed that machining
376
Fig. 7 Multivariate optimization plot
under RQL is useful, improving the chip flow by reducing
the friction due to the lubrication in the tool-chip interface.
& The multivariate optimization through the desirability
function showed that RQL is the best choice to minimize
surface roughness in the turning of CP-Ti Grade 4 among
the lubri-cooling methods tested. The lower surface
roughness values were obtained with RQL machining
using the optimized levels of cutting parameters (vc = 80
m/min; f = 0.08 mm/rev; ap = 0.2 mm).
& Another advantage of RQL is that a smaller LCC quantity
is needed compared to flood machining, which reduces
the deleterious effects associated with cutting fluids.
Consequently, RQL machining is more economical,
non-aggressive for human health, and environmentally
friendly than the flood coolant.
& Despite the better surface finish obtained with RQL, MQL
machining results improve with high cutting speed and
high depth of cut. Thus, the best results with this LCC
also allow the best productivity. Therefore, for high pro-
duction, MQL turning is the best strategy.
Table 5 Results of optimization validation tests
LCC Responses Predicted Validated
RQL Ra (μm) 0.32 0.46
Rz (μm) 2.15 2.63
Int J Adv Manuf Technol (2021) 113:365–378
& It is important to remember that, despite the multivariate
optimization aimed to minimize both Ra and Rz values,
this is not always the goal in the industry. The functions
developed may be combined with other data to find the
best machining conditions for different surface finishes,
aiming for sustainability, low energy consumption, high
tool lives, etc.
Acknowledgements The authors thank Primuss Co. for the workpiece
material, Quimatic/Tapmatic Co. for the nebulizer and cutting fluid ap-
plied in MQL/RQL conditions, Bondmann Chemistry Co. for the cutting
fluid used in flood machining, and LAMEF/UFRGS for the workpiece
chemical analysis.
Author contribution Each author contributed to the research presented in
this manuscript, approved the contents now presented, and agreed to the
compliance with ethical standards.
Funding This research did not receive any specific grant from funding
agencies in the public, commercial, or not-for-profit sectors.
Data availability The manuscript has no associated data in a data
repository.
Declarations
Ethics approval The manuscript is original and has not been submitted
for publication elsewhere (partially or in full). Also, the manuscript has
not been submitted to more than one publication for simultaneous
consideration.
Int J Adv Manuf Technol (2021) 113:365–378
Consent to participate Not applicable (this research did not involve
human subjects).
Consent for publication All authors consent to the manuscript’s publi-
cation in the IJAMT, should the article be accepted by the Editor-in-chief
upon completion of the refereeing process.
Competing interests The authors declare no competing interests.
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