Ionic liquids have recently acquired popularity as excellent lubricant additives due to their exceptional tribological and thermal properties. Hard turning of hardened steels (>45 HRC) poses challenges like high cutting temperatures, leading to rapid tool wear and increased costs. This study developed a unique cutting fluid using 1-butyl-3-methylimidazolium chloride ionic liquid in concentrations of 1, 3, and 5 wt.% to improve the machinability of AISI D2 hardened steel (57 ± 1 HRC) with a low-cost CVD-coated carbide tool. Results showed reduced cutting temperature, tool wear, and power consumption. The tool life was 51.5 min for flank wear (VBc = 0.2 mm) and 40 min for surface roughness criteria. Circularity error and carbon emissions were 0.02 mm and 1.827 kg CO2, respectively, with a machining cost of $ 0.909 per cut, making it an economical, and environmentally sustainable approach for hard turning.
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