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Magnetorheological fluid-based nanotexturing of tool inserts for turning of duplex stainless steel

ABSTRACT This paper deals with the study of the nanotexturing process of the cutting tool inserts with the influence of a magnetorheological fluid-based texturing method. The rake and flank surface of the cutting tool inserts were finished with a silicon carbide abrasive mixture of a magnetorheological fluid. Experimentation is conducted with input variables such as voltage, gap width, and polishing time to achieve the desired value of % reduction of surface roughness, polishing rate, andpolishing time. The surface roughness is found to be less than 40 nm for textured and 120 nm for non-textured inserts with a lesser polishing time. A higher polishing rate of the cutting tool inserts is achieved at a working voltage of 36 V and a gap width of 0.75 mm. The machinability characteristics of the nanotextured inserts are based on the cutting force; tool wear is studied for the turning operation of Duplex stainless steel. The tool flank wear is observed to be 0.63 mm, after 13th pass when turned with an unpolished insert and 0.612 mm after the 19th pass with a polished insert. From the results, it is found that the nanotextured inserts could achieve a tool life of 60% higher than the un-textured inserts in machining the duplex stainless steel.