Tribological Behavior and Surface Roughness Analysis of Workpiece Materials Under Dry Machining Conditions

Abstract

This study investigates the tribological properties and surface roughness of AISI D3 tool steel during dry machining using high-carbide, cemented-coated carbide tools on CNC machines. Tribological properties, including wear resistance and frictional characteristics, are critical factors in machining processes, significantly affecting the quality and performance of the finished product. The research examines the influence of key machining parameters, cutting speed, feed rate, and depth of cut on surface roughness and wear behaviour under dry conditions, emphasising the eco-friendly aspect of lubricant-free machining.

Experimental trials assessed the interaction between machining parameters and tribological responses, employing advanced metrological tools for surface texture analysis. The study identifies optimal machining conditions that minimize wear and achieve superior surface finishes while extending the tool life. Additionally, the investigation explores the microstructural effects on the machined surface and correlates them with variations in machining parameters.

The findings provide insights into the machinability of D3 tool steel in dry environments and offer practical guidelines for improving process efficiency and product quality in precision machining. This work contributes to sustainable manufacturing practices by eliminating coolant usage while maintaining high-performance standards.

The findings provide insights into the machinability of D3 tool steel in dry environments and offer practical guidelines for improving process efficiency and product quality in precision machining. This work contributes to sustainable manufacturing practices by eliminating coolant usage while maintaining high-performance standards.