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Machinability Investigation and Sustainability Assessment of Dry Cutting AISI1045 Steel Using Tools Configured with Shark-Skin-Inspired Structures and WS2/C Coatings

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Abstract

This paper primarily determined the suitable technique for the preparation of WS2/C coating by the analytical hierarchy process (AHP) with a keen focus on the criteria of coating property, deposition process, resource and equipment. Further, some cutting performances of six cutting tools with different treatments, including cutting forces, cutting temperatures, wear mechanisms, tool life, etc. were investigated in dry cutting AISI1045 steel. The optimal lubricating condition for dry cutting process was obtained when using the cutting tools configured with the combination of WS2/C coating and shark-skin-inspired structures. Finally, the sustainability assessment was carried out by the calculation of the product sustainability index (PSI). The highest PSI of 78.6% was obtained in case of the dry cutting experiment using WMT-2-N tools, which provided a suggested favorable alternative considering both product and manufacturing process. Thus, dry cutting AISI1045 steel using WMT-2-N tools seems to be an environmentally-friendly machining process and would be helpful to enhance sustainability.

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Abbreviations

γ 0 :

Rake angle (deg)

α 0 :

Clearance angle (deg)

κ r :

Cutting edge angle (deg)

λ s :

Edge inclination angle (deg)

f:

Feed rate (mm/r)

ap :

Depth of cutting (mm)

ν :

Cutting speed (m/min)

Ff :

Feed force (N)

Fp :

Radial thrust force (N)

Fc :

Tangential force (N)

μ :

Tool-chip friction coefficient

ϕ:

Shear angle (deg)

ξ :

Chip thickness ratio

ach :

Deformed chip thickness (mm)

acp :

Undeformed chip thickness (mm)

N:

Spindle speed (rpm

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Acknowledgements

This work is supported by the Natural Science Foundation of Shandong Province (ZR2018ZB0522), National Natural Science Foundation of China (51675311) and the China Scholarship Council.

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Xuemu Li, Jianxin Deng, Yang Lu & Dongliang Ge

  2. School of Mechanical and Electronic Engineering, Shandong Jianzhu University, Jinan, 250061, China

    Ran Duan

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  1. Xuemu Li
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Correspondence to Jianxin Deng.

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Li, X., Deng, J., Lu, Y. et al. Machinability Investigation and Sustainability Assessment of Dry Cutting AISI1045 Steel Using Tools Configured with Shark-Skin-Inspired Structures and WS2/C Coatings. Int. J. of Precis. Eng. and Manuf.-Green Tech. 9, 83–106 (2022). https://doi.org/10.1007/s40684-021-00330-x

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