Analysis of residual stresses under hard turning of AISI D2 hardened steel using TiAlN PVD-coated carbide insert for different cutting environments

Abstract

Although several studies have explored hard turning of difficult-to-machine steels, a comprehensive and comparative analysis of the residual stress behavior of AISI D2 steel under different advanced cooling and lubrication strategies, specifically nano Al₂O₃-based minimum quantity lubrication (MQL) and cryogenic liquid nitrogen (LN₂), remains limited. Existing literature primarily focuses on surface roughness (Ra) and tool wear, while systematic evaluation of subsurface residual stresses across multiple cutting environments using titanium aluminum nitride (TiAlN) PVD-coated carbide inserts is scarce. This gap motivates the present research, which aims to identify the most suitable cutting environment for achieving favorable residual stress profiles during hard turning of AISI D2. Here, AISI D2 hardened steel was turned using TiAlN-coated carbide inserts under four cutting environments: Dry, conventional wet cooling, nano Al₂O₃ MQL, and cryogenic LN₂. Cutting speed, feed rate, depth of cut, and rake angle were selected as control parameters common to all environments. The resulting Ra, cutting forces (N), and residual stresses were measured and analyzed. The influence of the machining parameters on the development of residual stresses was also examined under both favorable and extreme cutting conditions for each environment. The results clearly indicate that compressive residual stresses (σCRSs) were generated in all cutting environments, which is beneficial for enhancing fatigue resistance. Among the conditions studied, cryogenic cooling produced the maximum σCRS, demonstrating its superior capability to improve surface integrity during hard turning of AISI D2 steel. The current work focuses on important machining issues, particularly with AISI D2 steel work material. Sustainable manufacturing is supported by the use of cryogenic cooling and nano-based MQL. Adopting such machining conditions will increase the service life and dependability of components.

Keywords

Residual stresses AISI D2 steel hard turning nano MQL cryogenic

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