Journal of Manufacturing Processes 31 (2018) 650–661

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Journal of Manufacturing Processes

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Influence of cutting speed and cooling method on the machinability of

commercially pure titanium (CP-Ti) grade II
Akhtar Khan, Kalipada Maity ∗
Department of Mechanical Engineering, National Institute of Technology Rourkela India

a r t i c l e i n f o a b s t r a c t

Article history: The present investigation aims in highlighting the influence of cutting speed and an eco-friendly cooling
Received 24 April 2017 technique during finish turning of CP-Ti grade 2. Experiments were performed at three distinct machining
Received in revised form modes viz. dry cutting (DC), flood cooling (FC) and minimum quantity lubrication (MQL) using carbide
21 December 2017
inserts. Water soluble oil and vegetable oil were used as cutting fluids with FC and MQL respectively. The
Accepted 23 December 2017
work material was turned at three different cutting speeds i.e. 51, 67 and 87 m/min whereas feed rate and
Available online 5 January 2018
depth of cut were kept as constant at 0.12 mm/rev and 0.5 mm respectively. A comprehensive exploration
on the cooling effects of vegetable oil based MQL method on some of the key machinability aspects such as
Keywords:
Minimum quantity lubrication
cutting force, tool wear, friction coefficient, chip morphology, chip reduction coefficient, micro hardness
Carbide insert of machined surface, surface roughness and machining temperature is reported. The aforesaid turning
CP-Ti grade 2 responses were recorded and compared in order to exhibit the feasibility of MQL approach in comparison
Machinability with dry and flood cooling approach. The results obtained during the investigation clearly established
the superiority of implementing MQL for achieving improved machinability within a specified range of
process parameters.
© 2018 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.

1. Introduction Therefore, the most preferable range of cutting speed in titanium

Titanium and its alloys have become best material choices in
aerospace, marine, petro chemical, medical, nuclear and energy
industries due to their inherent assets such as highest strength-to-
weight ratio and excellent resistance to corrosion and deformation
under high temperature and pressure [1]. However, the foremost
challenge that encounter during titanium machining includes gen-
eration of high temperature at cutting zone owing to its low thermal
conductivity. The chemical affinity of these alloys are also reported
more than that of other similar materials. Therefore, titanium and
its alloys are specifically characterised as hard-to-cut type material.
Poor thermal conductivity leads to rapid upsurge in temperature
near machining zone particularly at chip-tool interface region. High
temperature at cutting zone sturdily accelerates tool wear and
hence reduces the tool life to a great extent [2]. Further, titanium
and its alloys are capable of maintaining their strength even at
higher temperature (because of highest strength-to-weight ratio)
which at the same time contributes to deteriorate the performance
of cutting tool inserts while machining at higher cutting speeds.
∗ Corresponding author.
E-mail addresses: 513ME1057@ntrkl.ac.in (A. Khan), kpmatiy@nitrkl.ac.in
(K. Maity).
machining was suggested between 30–60 m/min [3,4]. High chem-
ical affinity of titanium alloys often offers severe tool damage at
pre mature stage beyond the aforementioned speed limit. There-
fore, in order to attain a reasonable tool life along with good surface
quality even at high cutting speeds, an efficient and effective cool-
ing or lubrication approach should be applied. In such situations,
cutting fluids such as water soluble oil and vegetable oil are strate-
gically employed as cooling media to reduce the temperature at
chip-tool interface region. It also helps in improving surface qual-
ity and wear resistance in combination with substantial reduction
in cutting forces [1–7]. Priarone et al. [6] investigated the effect
of lubrication technique on tool wear and surface quality during
machining of Ti-48Al-2Cr-2Nb intermetallic alloy. They noticed a
significant reduction in both the aforesaid machining characteris-
tics after implementing MQL method in comparison to dry cutting.
The percentage reduction in tool wear and surface roughness was
perceived nearly 50% and 30% respectively. In a different study con-
ducted by Dhar et al. [8] revealed a notable diminution in machining
temperature (approximately 5–10%) by adopting MQL approach.
Similarly, Vikram et al. [9] also tested the performance of TiCN and
ZrN coated tools during hard turning of AISI 4340 alloy steel in both
dry and MQL cutting conditions. The results indicated a remark-
able decrease in the cutting force, machining temperature and

https://doi.org/10.1016/j.jmapro.2017.12.021
1526-6125/© 2018 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661 651

Fig. 1. FESEM images of (a) Microstructure and (b) EDS spectra of CP-Ti grade 2.

Fig. 2. Photographic view of the present investigation.

surface roughness (roughly 42%, 29% and 39% respectively) with
the minimal fluid application when compared to its dry machining
counterpart. Thus, the world wide consumption and disposal of cut-
ting fluids are interestingly enhanced. The consumption of cutting
fluids in the U.S.A. was recorded about 100 million gallons/year
whereas in Germany it was about 2 million gallons/year [10,11].
The rapid growth in utilization of cutting fluids upraised a serious
problem due to some of its adverse effects. Since, most of them
are not biodegradable and hence they introduce an adversarial and
hostile situation to men, machine and environment. Continuous
interaction of machine tool operator with cutting fluid possibly
cause serious lung and skin diseases [12,13]. Indecorous removal
and dumping of these cutting fluids might result in ground, air and
water pollution. Additionally, the costs associated with cutting flu-
ids are quite higher than that of labour and overhead costs. Past
research indicated that, about 16% of the total production cost is
covered by the cost of cutting fluid used during the process. These
costs reach up to 30% when machining difficult-to-cut type mate-
rials like titanium and its alloys [14,15].
An extensive work has been reported based on critical analysis
of an economic and eco-friendly machining of hard-to-cut mate-
rials such as titanium and nickel based alloys with an objective to
accomplish considerably improved machinability [16–20]. In this
regard, the capability of coolant in bringing down the machining
652 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661

Fig. 3. Variation in cutting force at speed of (a) 51 m/min, (b) 67 m/min and (c) 87 m/min.

Table 1 Table 2
Chemical composition of CP-Ti grade 2. Tool geometry.

Element Wt. (%) Parameter

Carbon 0.08 – 0.1 Insert shape Square

Nitrogen 0.03 Insert clearance angle 0◦
Oxygen 0.25 Tolerance ± 0.002
Iron 0.30 Cutting edge length 12 mm
Hydrogen 0.015 Insert thickness 04 mm
Titanium Balanced Nose radius 0.8 mm
Holder style PSBN
Shank height 20 mm
Shank width 20 mm
temperature was tested and found appreciable [1–24]. Study con- Tool length 125 mm
ducted by Ezugwu and Bonney [25] indicated that the conventional Cutting edge length 12 mm
cooling approach is effectively helpful during low cutting speed
(40 m/min). Further, during high speed machining this method is
neither favourable nor cost-effective. On the other hand, the con- tal implants, endodontic files and orthodontic wires, partial and
ventional flood cooling technique consumes more cutting fluid and complete denture framework [37,38]. It is also used for the con-
hence the chances of pollution along with production cost is more. struction of several non-structural parts of an air craft such as
Therefore, to curtail the consumption and improve the penetrabil- floor support structure in the galley and lavatory areas, ducting
ity of cutting fluids particularly at tool-chip interface region, several for anti-icing and environmental control systems, pipes and tubes
economic and eco-friendly techniques such as minimum quantity in the lavatory system etc. [39]. In addition to that, CP-Ti is not
lubrication (MQL), atomisation-based cutting fluid (ACF) and small heat treatable and hence exhibits good weldability. In spite of the
quantity lubrication (SQL) have been established [1–35]. Pusavec aforesaid qualities, the extraction and machining cost of this alloy is
et al. [21] in their investigation explored the promising capability more than that of any other similar alloys. Therefore, efforts should
of MQL technique in decreasing cutting force and improving surface be concentrated towards the cost reduction without compromis-
finish and tool performance than that of dry cutting environment. ing the quality of the end product. In this situation, an in-depth
However, abrasion, attrition and notch wear were identified as vital analysis of various machinability characteristics become essen-
tool failure mechanisms during milling of Inconel 718 at high cut- tial to confirm higher productivity, good dimensional accuracy in
ting speed under MQL condition [36]. association with reduced cost. Therefore, the present investigation
Literature of the past research work suggests several cooling or focuses on turning of CP-Ti grade 2 with uncoated carbide inserts
lubricating approaches to improve sustainability during machin- under dry and wet (flood and MQL) cutting environment. Machin-
ing of hard-to-cut materials like titanium and its alloys. Although, ing responses (both qualitative and quantitative) were evaluated
an extensive work on machining of titanium alloy (Ti-6Al-4V) and and compared to demonstrate the feasibility of MQL in comparison
nickel base alloy (Inconel 718) has already been reported, machin- to dry and flood cooling method.
ability characteristics of CP-Ti grade 2 with substantial difference
in properties are reasonably not reported so far. The work material 2. Experimental details
used in this study, owing to its amazing resistance to corrosion, light
weight and biocompatibility extensively used in medical, marine 2.1. Testing material
and petrochemical industries apart from its common use in space
craft, defense, nuclear and aerospace sector. Tissue inertness along The workpiece used in this investigation was a cylindrical
with good biocompatibility of this material makes it useful for den- bar of commercially pure titanium (CP-Ti) with the dimension of
 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661 653

Fig. 4. Variation in app at speed of (a) 51 m/min, (b) 67 m/min and (c) 87 m/min.

Fig. 5. Variation in machining temperature at speed of (a) 51 m/min, (b) 67 m/min and (c) 87 m/min.

Ø50 mm × 500 mm. Fig. 1 depicts the microstructure along with
EDS spectra of the top surface of the work material. A notable
amount of fine alpha (␣) grains were seen at the top surface which
signified the presence of titanium in a huge percentage while the
small black spots represent the beta (␤) phase. The chemical com-
position of the work part is shown in Table 1.
2.2. Cutting insert and tool holder
An ISO designated (SNMG 120408) square shaped cutting tool
inserts were used in the present investigation. The inserts were
manufactured by Kennametal and having grade of K313. A new
tool tip was used for every experimental run. A tool holder with ISO
designation of PSBNR 2020K12 (Kennametal, Made in Bulgaria) was
utilized during experimentation. The tool geometry of the cutting
insert and tool holder are represented in Table 2.
2.3. Experimental procedure
The workpiece material was primarily turned on a heavy duty
lathe (HMT, Made in India) with commercially available uncoated
cemented carbide inserts in three distinct cutting environment
654 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661

Fig. 6. Variation in surface roughness at speed of (a) 51 m/min, (b) 67 m/min and (c) 87 m/min.

Fig. 7. Variation in flank wear at speed of (a) 51 m/min, (b) 67 m/min and (c) 87 m/min.

viz. dry, flood and MQL. The effects of cutting speed and cooling
approach were studied and compared with dry machining. The
experiments were carried out at three cutting speeds i.e. 51, 67,
and 87 m/min for machining duration of 30, 60, 120, 180 and 240 s
whereas the other two machining parameters were kept constant
(feed rate = 0.12 mm/rev and depth of cut = 0.5 mm). A photographic
view of the present investigation is shown in Fig. 2. The cut-
ting force essentials viz. tangential (Fz ), thrust (Fy ) and radial (Fx )
were measured with the help of a three dimensional piezoelectric
dynamometer (Manufactured by Kistler Instrument, Switzerland).
Each components were recorded twice for better accuracy and then
the resultant cutting force (Fc ) was calculated for further analysis.
The machining temperature at tool-work interface was measured
using a thermocouple by fixing its probe just below the tool tip. A
0.5 mm probe was placed at the tool-work interface and the approx-
imate cutting temperature was recorded. In order to reduce the
chances of heat transfer an insulation of Teflon tape was provided
to the different parts of machine tool setup such as head stock, tail
stock and tool holder. A roughness tester manufactured by Tay-
lor Hobson (Model: Surtronic 3+) was used to measure the surface
of the turned part. The surface value was recorded at four differ-
ent locations (roughly 90o apart) around the circumference of the
machined work material and the average value was taken. Wear
on the flank and rake faces of the cutting inserts were measured
 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661 655

Fig. 8. Optical microscopic images depicting progression of flank wear.

with the help of an optical microscope (Manufactured by Carl Zeiss,
Model: AxioCam ERc 5s) and further analysed under a field emis-
sion scanning electron microscope (FESEM) for each experimental
trial. In order to confirm better measurement accuracy, tool wear
was recorded at three different locations on the wear out faces
(Flank and rake face) and the average values were considered for the
investigation. A field emission electron microscope (FESEM) along
with energy dispersive spectroscopy (EDS) was used to examine
the microstructure of the work part and chip morphology. Prior
to study the morphology, the chips were kept into an epoxy resin
mould using cold mounting technique. These test samples were
then polished with the help of different grades of polishing papers.
An optical microscope (Stereo zoom) was utilized to measure the
chip thickness. For better statistical accuracy the measurement was
taken at three different locations and the average value was taken
during analysis. In order to carry out the study of the micro hardness
of the machined surface obtained in all the three cutting condi-
tions, Vickers micro hardness tester (Manufactured by Leco, Model:
LM248AT) was employed. The micro hardness data was recorded
around the circumference of the turned part on the cross sectional
surfaces along a straight line from the edge towards the centre.
The gap between two consecutive indentations was kept 10 ␮m.
656 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661

Fig. 9. Optical microscopic images depicting progression of crater wear.

Moreover, the dwell time and test load were set 10 s and 0.025 N
respectively.
3. Results and discussion
3.1. Cutting force
The portrays study explores a critical examination of variation
of cutting forces in different machining environment because it is
strongly co-relates with the other important cut qualities such as
tool wear, machining temperature, surface quality, etc [40]. Fig. 3
portrays the variation in resultant cutting force with respect to
machining duration under dry, flood and MQL mode of cutting.
The figure indicates that the resultant cutting force exhibits an
increasing trend with machining time for cutting speed of 51 m/min
(Fig. 3a) under all the three machining environment. However, it
decreases slightly after turning duration of 180 s for cutting speeds
of 67 m/min and 87 m/min respectively. It might be contributed to
the thermal softening of the work material at elevated tempera-
ture and higher cutting speed. High speed continuous machining
 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661
Fig. 10. FESEM images of rake surface.
also contributes in lowering the shear strength of the work piece
and hence reduces the resultant cutting force significantly. Inter-
estingly, MQL mode of machining resulted a remarkable reduction
in cutting force of around 46% and 16% in comparison with dry
and flood cooling conditions respectively. Similar trend has also
been reported by former researchers [41,42]. It is evident from the
figure, that the vegetable oil based minimum quantity lubrication
approach offers promising reduction in the machining force. Owing
to an appropriate arrangement for an efficient delivery of coolant in
combination with appreciable lubricity offer in this approach, sus-
tainable outcomes like less tool wear and better surface quality are
yielded. Moreover, no significant variation in the resultant cutting
force was seen between MQL and flood cooling mode for cutting
speeds of 67 m/min (Fig. 3b) and 87 m/min (Fig. 3c).
3.2. Apparent coefficient of friction
Analysis of apparent coefficient of friction (app ) is one of the
important tasks in turning of work material under dry, flood and
MQL cutting conditions. This phenomenon in general occurs at tool-
chip interface and mainly governed by tool wear and machining
environment. The value of app was determined using Eq. (1) [43].
Fc Sin + Ft Cos
=
Fc Cos − Ft Sin
657
where,  is called orthogonal rake angle ( = 6◦ ) and Ft represents
the thrust force which can be evaluated by using Eq. (2).

Ft = Fr2 + Ff2 (2)
where, Fr and Ff represents the radial and feed force respectively.
Fig. 4 depicts the variation attained in app with respect to
machining duration. The aforementioned figure reveals that the
apparent coefficient of friction was less under flood and MQL modes
of machining in comparison with dry cutting environment for all
the studied range of cutting speeds. This is because of the cool-
ing and lubricating effects of cutting fluids. The lubricating action
reduces the temperature at chip-tool interface region and hence
cutting forces bring down under MQL condition. Thus the friction
coefficient between tool-chip contact areas becomes lower when
compared to dry and flood condition. This also contributed to the
non-uniform nature of app at higher cutting speed as evident from
Fig. 4(c).
3.3. Machining temperature
Cooling approaches in machining are employed mainly with
an aim to reduce the cutting temperature. These are also help-
ful in preventing the cutting tools from severe damage such as
abrasion, adhesion and diffusion which are strongly co-related
to machining temperature. Moreover, machining titanium alloys
at elevated temperature leads to rapid tool wear. The variation
recorded in cutting temperature during the investigation are shown
(1)
in Fig. 5. It is evident from the figure that, with increase in cutting
658 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661
Fig. 11. FESEM images of chips produced under (a) dry, (b) flood and (c) MQL conditions.
speed, temperature at machining zone increased dramatically due
to improved friction at tool-work interface. However, the machin-
ing temperature observed under MQL mode was comparatively
less in comparison with dry and flood modes for all the studied
range of cutting speeds. A remarkable reduction in cutting temper-
ature was noticed under MQL condition than that of dry (around
65%) and flood (around 48%) environments. This is because, the
heat transfer takes place during MQL machining mode through
convection and evaporation. Application of MQL excellently facili-
tates the fluid droplets to reach at tool-work interface (machining
zone) which offer an efficient heat transfer thus provides improved
lubrication leading to low machining temperature [5]. This might
be contributed to the superiority of atomised coolant particles to
effectually enter into the cutting zone.
3.4. Surface roughness
Typical surface roughness (Ra ) values measured after turning of
the work part under all the three cutting environments are shown
in Fig. 6. Slightly lower Ra values were observed at higher cutting
speeds (67 m/min and 87 m/min) when compared with the lower
one (51 m/min). The aforesaid figure revealed that, surface rough-
ness value decreases with increase in cutting speed. This indicated
that the machined surface tend to become smoother for high speed
continuous machining. This might be contribute to the adhesion
of the work material at tool nose during machining at elevated
temperature. High machining temperature resulted in softening of
work material which reduces the induced cutting forces and hence
a good surface finish was achieved. A similar trend was reported by
Che-Haron and Jawaid [44] in their study when machining tita-
nium alloy (Ti-6Al-4V). In addition, at higher cutting speed, the
chips produce and break away near the tool tip with very less mate-
rial deformation which in turn preserves the surface characteristics
of machined part causing improved surface quality. On the other
hand, surface roughness recorded under MQL condition was all
along lower in comparison with dry and flood machining. This is
due to the fact that, MQL mode offers more effective cooling and
lubrication than that of dry or flood mode. As a result of which a sig-
nificant reduction in friction could be attained in combination with
high rate of heat transfer. Hence, surface roughness was observed
less when compared to flooded machining. However, in case of dry
machining no cutting fluid was supplied resulting in high friction
and low heat transfer which in turn contributed to high surface
roughness.
3.5. Tool wear
The temperature generated at machining zone is primarily
responsible for rapid tool wear when machining titanium alloys.
Therefore, high machining temperature often introduced severe
 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661
Fig. 12. Variation in chip reduction coefficient at speed of (a) 51, (b) 67 and (c) 87 m/min.
tool wear phenomenon like chipping, fracture of the tool nose and
plastic deformation. There are numerous wear mechanism which
can significantly affect the tool wear during turning of CP-Ti grade
2. The major wear mechanisms noticed in the current investigation
were abrasion, diffusion, plastic deformation and chipping.
3.5.1. Analysis of flank wear
Tool wear during turning of CP-Ti grade 2 was characterised
by flank and crater wear and subsequently studied with the help
of optical microscope and FESEM. Fig. 7 shows the progression of
average flank wear for different machining duration at the speeds
of 51, 67 and 87 m/min under both dry and wet (flood and MQL)
cutting conditions. A rapid growth in flank wear was noticed after
120 s of machining at high cutting speeds (67 and 87 m/min), espe-
cially when machining under dry cutting environment. On the other
hand, no significant variation was observed initially up to 60 s for
all the studied range of cutting speeds under all cutting conditions.
However, the superiority of utilizing MQL was more prominently
visible for high speed continuous machining which offers better
cooling and lubrication in comparison with dry and flood machin-
ing leads to less wear. Therefore, vegetable oil based MQL approach
emerged as a sustainable alternative for machining CP-Ti grade 2.
Fig. 8 demonstrates the optical microscopic images of flank wear
along with machining duration under both dry and wet (flood and
MQL) cutting environment. High chemical reactivity of titanium
alloys leads to material adhesion on the tool face which results in
the formation of built-up edge (BUE). This phenomenon which is
attributed to higher friction was seen after machining duration of
180 s under both (dry and flood) cutting conditions. Furthermore,
the aforementioned figure also indicates that the tendency of BUE
formation was more prominent during dry cutting when compared
to flood and MQL modes of machining. Excellent cooling in com-
bination with good lubrication resulted in significant reduction in
friction and thus contributed to the outstanding performance of the
cutting inserts particularly under MQL mode even at higher cutting
speed.
659
3.5.2. Analysis of crater wear
Wear on the rake face of the cutting inserts while turning tita-
nium alloys is primarily governed by the contact mechanism at
tool-chip interface area. High temperature and pressure at this
region are the major factors which offers diffusion and adhesion
types of wear. Fig. 9 shows the optical microscopic images of rake
faces for both dry and wet machining at different cutting speeds and
machining duration. More damages at rake faces are predominantly
visible under dry cutting than that of flood and MQL machining.
The major tool wear modes identified during this investigation
were plastic deformation, formation of built-up edge (BUE) and
built-up layer (BUL) as depicted in Fig. 10. Adhesion of the work
material was the most significant wear mechanism under both dry
and wet machining. The aforesaid figure (Fig. 10) also shows the
formation of BUE and BUL due to plastic deformation of the work
material. Lower thermal conductivity and higher chemical affin-
ity of the work part (CP-Ti grade 2) might be contributed to this.
Interestingly, stronger effects of applying MQL technique over dry
and flood approach, is evidenced from above mentioned figures
(Figs. 9 and 10). This also exhibits the better performance capability
of vegetable oil based MQL machining.
3.6. Chip morphology
The morphology of the top surface of chips produced after
turning of the work part was deeply analysed with the help of
FESEM images as depicted in Fig. 11. In general, titanium and
its alloys are characterised by serrated chips which are strongly
evidenced from the aforesaid figure. This phenomenon is primar-
ily attributed to shear localisation and plastic deformation of the
work material during machining. Moreover, machining titanium
at higher cutting speed (87 m/min) causes high tool-chip friction
in combination with high plastic deformation and hence produces
more serrated chips under dry condition. Therefore, degree of ser-
ration was observed to be more under dry cutting environment
when compared to that under flood and MQL environment. This
can be attributed to high temperature generation at cutting zone
while machining the work material under dry condition. Such high
660 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661

machining temperature leads to a remarkable enhancement in the

plasticity of the work part. On the contrary, deformation of the
workpiece material under wet (flood as well as MQL) condition
was less due to lower machining zone temperature. This might be
introduced side flow of chip material, as evident from the aforesaid
figure (Figs. 11b and c).

3.7. Chip reduction coefficient

Chip reduction coefficient () is also known as the measure of

deformation of the workpiece which is primarily influenced by the
formation of BUE and amount of friction at the tool-chip interface.
It can be evaluated using Eq. (3).

tc
 = (3)
to

where, tc is called chip thickness and to is known as uncut chip

thickness which can be calculated with help of Eq. (4).

to = f. sin ϕ (4)

where ϕ is defined as approach angle of the cutting insert (ϕ = 75◦

for SNMG inserts) and f denotes the feed rate (mm/rev). Fig. 12
represents the variation in  under both dry and wet machining
for different machining duration and cutting speeds. Evidently,
chip reduction coefficient under dry cutting environment was high
owing to more friction. However, no significant variation in  was
observed under flood machining when compared to MQL mode of
operation for all the studied range of cutting speeds.

3.8. Micro hardness analysis

Fig. 13, shows the variation attained in micro hardness on the

top surface of the turned part of CP-Ti grade 2 for both dry and wet
(flood and MQL) machining condition after a machining duration
of 240 s and cutting speeds of 51, 67 and 87 m/min. The aforemen-
tioned figure reveals that micro hardness profile recorded under
MQL mode of machining lies between those under dry and flood
machining for all the studied range of spindle speeds. Furthermore,
it decreases from the surface region (edge) to sub-surface (towards
centre) of the machined part. On the other hand, different cool-
ing approaches (flood and MQL) did not have noticeable impact
in altering the micro hardness in comparison with dry condition.
Additionally, a shallow gradient of micro hardness was observed
Fig. 13. Variation in micro hardness profile at speed of (a) 51, (b) 67 and (c)
as depicted in the same figure. This kind of shallow variation in
87 m/min.
the hardness profile of machined part is strongly related to cutting
zone temperature in combination with cooling approach. Temper-
ature of the work surface might be more at high machining speed resulted in lowest cutting temperature whereas the same was
(87 m/min). At the same time, very less amount of heat would be recorded significantly higher under dry cutting environment.
• A remarkable reduction in cutting force (46% and 16%) was
carried away by the chips due to such high cutting velocity. There-
fore, in case of wet machining micro hardness profile was observed observed when turning CP-Ti grade 2 under MQL mode than that
to be less at surface centre area in comparison with sub-surface of dry and flood machining environment. This also ensures less
region. consumption of cutting power.
• Tool wear on the flank face was recorded less by 57% and 34%
Fig. 13 Variation in micro hardness profile.
under MQL machining in comparison with dry and flood condi-
tion respectively.
4. Conclusions • Superior surface finish was observed under vegetable oil based
MQL cutting environment when compared to dry and flood cut-
The current study aimed at investigating the feasibility of veg- ting environment.
etable oil based MQL approach during machining of hard-to-cut • No significant hardening effect was noticed at the surface and
titanium alloys particularly CP-Ti grade 2. The following conclu- sub-surface regions of the turned part under wet condition in
sions may be drawn after successful completion of the experiment. comparison with that under dry condition.
• Vegetable oil based MQL approach can be successfully applied to
• Cooling approaches (flood and MQL) were intensely capable in get an improved machinability in turning of CP-Ti grade 2 within
reducing machining zone temperature. MQL mode of operation the specified range of process parameters.
 A. Khan, K. Maity / Journal of Manufacturing Processes 31 (2018) 650–661
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