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Procedia CIRP 00 (2017) 000–000 Procedia CIRP 77 (2018) 437–440 www.elsevier.com/locate/procedia
8th CIRP Conference on High Performance Cutting (HPC 2018)
Influence of graphite nanoadditives toMay vegetable-based oil on machining 28th CIRP Design Conference, 2018, Nantes, France performance when MQCL assisted hard turning A new methodology to analyze the functional and physical architecture of b Oleksandr Gutnichenko Volodymyr oriented Bushlyaa, Sverker Bihagen , Jan-Eric Ståhla existing products for ana*,assembly product family identification a a
Division of Production and Materials Engineering, Lund University, Lund, S-22100, Sweden
Accu-SvenskaDantan, AB, Västerås, 72132, Sweden Paul Stief *, Jean-Yves Alain Etienne, Ali Siadat b b
* Corresponding author. Tel.: +4-670-220-5694. E-mail address:
[email protected] École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address:
[email protected]
Abstract
The current study demonstrates through experiment, the effect of solid lubricant assisted minimum quantity cooling lubrication (MQCL) when Abstract turning tempered (~60 HRC) alloyed steel Uddeholm Caldie with cemented carbide tools on the process performance. In MQCL application, nanosized graphite nanoplatelets (GnP) solid lubricant powder was dispersed (0.2% vol.) in rapeseed oil based lubricant “ECOLUBRIC”. The Ineffect today’s business environment, trend towards moreMQCL product variety and is unbroken. this development, need of of cutting parameters at drythemachining and with lubrication on customization the machined surface finish,Due tooltoforces, tool wear andthevibrations agile and reconfigurable generated were studied. production systems emerged to cope with various products and product families. To design and optimize production systems well as to choose the by optimal product matches, product analysis areCC needed. Indeed,license most of the known methods aim to © 2018 as The Authors. Published Elsevier Ltd. This is an open access articlemethods under the BY-NC-ND © 2018aThe Authors. Published by Elsevier Ltd. analyze product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and (http://creativecommons.org/licenses/by-nc-nd/3.0/) This isofancomponents. open access This articlefact under the CCanBY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) nature impedes efficientScientific comparison and choice of8th appropriate product family combinations for the production Peer-review under responsibility ofresponsibility the International Committee of the CIRP Conference on High PerformanceHigh Cutting (HPC Selection and peer-review under of the International of the 8thphysical CIRP Conference system. A new methodology is proposed to analyze existing products Scientific in view of Committee their functional and architecture.onThe aimPerformance is to cluster 2018). Cutting (HPC 2018). these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable assembly systems. Based on Datum FlowMQCL; Chain,modified the physical structure of thenanoplatelets products is (GnP); analyzed. are identified, and Keywords: hard turning; Uddeholm Caldie; vegetable oil; graphite tool Functional wear; surfacesubassemblies finish; vibrations a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the similarity between product families by providing design support to both, production system planners and product designers. An illustrative example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of 1. Introduction to-machine materialsapproach. that usually requires a significant amount thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed © 2017 The Authors. Published by Elsevier B.V. of coolant. However, consumption rate of cutting fluids can be Peer-review of the scientific committee of the 28th CIRP Design Conference Cuttingunder fluidresponsibility is an indispensable constituent of machining potentially decreased2018. by means of MQL technique in case of at
processes performing the functions of coolant/lubricant and least a comparable process performance with those for a flood influencing on the chip formation processes in the cutting zone. cooling. Regarding latter, experimental data, unfortunately, Application of the fluids results in improvement of machining differ quite much for different studies that, in general, can be accuracy and surface finish, an extension of tool life as well as explained by specifics of experimental setups and conditions. in a chips disposal from the working zone. On the other hand, A practice that characteristics MQL-wise techniques are not still 1. Introduction of the product shows range and manufactured and/or it is well known that cutting fluids have a hazardous impact on assembled widespreadin in the industry even though the method is well this system. In this context, the main challenge in theDue environment health. Whereas difficultofto modelling known forand decades. Thisis isnow an evidence at least, to the and fasthuman development in theit isdomain analysis not only of, to cope withcomplex single completely get rid of the coolants in machining, a conceivable nature of MQL assisted machining process and many studies communication and an ongoing trend of digitization and products, a limited product range or existing product of families, way for resolving the problem is a dramatic reduction of their but have mainly character of case-studies as most of them in the digitalization, manufacturing enterprises are facing important also to be aable to analyze and to compare products to define amount in the process together with a replacement of harmful field of metal cutting. challenges in today’s market environments: a continuing new product families. It can be observed that classical existing components the fluids are comprised A promising solution The families present study is a one in more attempt to lookorinside the tendency towards reduction of productof. development times and product are regrouped function of clients features. to the requirements is a minimum quantity lubrication (MQL) process of MQL assisted turning the chromium-molybdenumshortened product lifecycles. In addition, there is an increasing However, assembly oriented product families are hardly to find. and its modifications in combination with cryogenic vanadium alloyed tool steel Uddeholm Caldie use of demand of customization, being at the same time intechnique, a global On the product family level, products differwith mainly in pure two etc. [1]. The techniques may be improved by a use of mineral and modified with graphite nanoplatelets (GnP) vegetablecompetition with competitors all over the world. This trend, main characteristics: (i) the number of components and (ii) the oils modified by micronanodispersed as well as type based The article the results of theelectronical). experimental which is inducing the and development frommaterials macro to micro of oil. components (e.g.reports mechanical, electrical, by utilization of vegetable oils instead of mineral ones [2]. study aimed at the assessment of the performance of markets, results in diminished lot sizes due to augmenting Classical methodologies considering mainly singlemachining products All mentioned is an urgent problem for machining difficultadvanced strength steel (AHSS), with coated cemented product varieties (high-volume to low-volume production) [1]. or solitary,high already existing product families analyze the To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which 2212-8271possible © 2018 The optimization Authors. Published by Elsevier Ltd. an open access causes article under the CC BY-NC-ND licensean efficient definition and identify potentials in This the is existing difficulties regarding (http://creativecommons.org/licenses/by-nc-nd/3.0/) production system, it is important to have a precise knowledge comparison of different product families. Addressing this Keywords: Assembly; Design method; Family identification
Peer-review©under of the International Scientific Committee of the 8th CIRP Conference on High Performance Cutting (HPC 2018).. 2212-8271 2018responsibility The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) Selection © and peer-review under responsibility of the International Scientific Committee of the 8th CIRP Conference on High Performance Cutting 2212-8271 2017 The Authors. Published by Elsevier B.V. (HPC 2018). Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. 10.1016/j.procir.2018.08.281
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carbide tools. Detailed analysis of the influence of lubricant type and cutting conditions on tool wear, tool life, surface finish, and process dynamics and stability during machining is presented. 2. Materials and methods 2.1. Test setup and machining conditions All tests are performed on a Boehringer Göppingen VFD engine lathe with a motor power of 30 kW and spindle speed rated up to 1800 rpm. The workpiece material was a tempered Caldie steel (~60 HRC) (Uddeholm, Sweden). Continuous longitudinal turning tests were done on the steel rods 70×350 mm with micro-grain coated CC tools of type DNMG150608MF1, grade TH1000 (SECO Tool AB) appropriate for finishing and medium machining. The tool provides a chipbreaker with rake angle 146, cutting edge radius 25 µm, and chamfer angle 0. TH1000 TiSiN-TiAlN nanolaminate PVD-coated grade enables manufacturers to productively tackle a wider variety of ISO H5-H10 applications as well as maintain long tool life when machining hardened steels, from 50-62 HRC, hard surfaced components and superalloy materials. A toolholder was of PDJNR 2525 M15 Jet type with a system of internal passages to provide MQL lubricant at a rake and flank faces during machining (Fig. 1 a). The inclination and clearance angles of the insert-toolholder system are = -6 and = 6 for all cutting geometries, respectively.
Fig. 1. (a) Setup for MQL assisted turning; (b) SEM image of GnP particles.
Cutting conditions were selected to correspond the range from finishing to medium turning operations where DOC was kept constant for all tests ap = 0.2 mm. Feed rate and cutting speeds were selected as follows: f = 0.08, 0.125, 0.16 mm/rev; vc = 60, 80, 100 m/min. The range covers conventional cutting speeds recommended by tool manufacturer. The machining tests were performed at dry conditions and with use of a pure and modified with GnP vegetable oil as a cooling/lubricating media for MQCL assisted turning. 2.2. Cooling/lubrication conditions The rapeseed oil (ECOLUBRIC E200L) was delivered by Accu-Svenska AB (Sweden). Some characteristics of the oil can be found in [1]. Nanoadditives (GnP) were produced by a sonication of thermally expanded graphite (TEG) in a solution (1 g of TEG per 120 ml of 10% (vol.) alcohol solution) during 24 hours in an ultrasonic dispenser with a power of 350W. SEM image of GnP particles is illustrated in Figure 1 b. The average size of platelets was around 1 µm and 50 nm in thickness. A modification of oil was performed by adding 0.2% (vol.) of the GnP suspension into the pure oil with a persistent stirring by a
magnetic stirrer during 10 min. Oil-GnP suspension remains stable around 20 days with an insignificant sedimentation. Original and modified oils were supplied to cutting zone by MQL Ecolubric Buster System provided by Accu-Svenska AB. The flow rate of lubricant mist was set up as 15 ml/h supporting the aim of a minimum environmental impact, whereas the air pressure was kept constant at 0.5 MPa. 2.3. Measurements and analysis The data acquired from all types of tests are acceleration of the tooltip and cutting forces in three mutually perpendicular directions. Tool wear and wear morphology and surface quality were also determined. The study of worn cutting edges were performed by an optical (Alicona InfiniteFocus Real3D) and electron (Tescan Mira3 High Resolution Schottky FE-SEM) microscopies. A three-axis piezoelectric dynamometer Kistler 9129АА was used to measure cutting forces. Acceleration signals are acquired with use of B&K sensors (type 8309, frequency range up to 60 kHz). Force and acceleration spectra were amplified and recorded simultaneously at sampling rates of 1 kHz and 120 kHz, respectively. Signal processing was performed using Matlab. The surface finish parameters are measured with a portable roughness tester Mahr MarSurf PS10 after each pass at least 5 times along the workpiece in a feed direction. 3. Results and discussion Application of coolants/lubricants in machining results in a change of a heat dissipation or/and redistribution in the cutting zone between tool, workpiece, chips, and environment; lubrication of interfaces between tool, chips and workpiece surfaces resulting in a reduced heat generation and a decrease of adhesion between tool and workpiece materials. These effects also suppose an attenuation of adhesive and diffusive wears mechanisms related to chemical reactions in the cutting zone as well as an abrasive impact on the tool surfaces, to a lesser extent. It is well known that the decrease in a friction and adhesion interactions in cutting zone influences on the chip formation mechanism resulting also in a decrease of the contact length of the tool rake and chips and its variation during machining. At these conditions, it is more reasonable to study not only mean or RMS values of forces and vibrations but also an evolution of their variation in time. Hence, the variations in the contact length and chip segment size should affect the system behavior in a frequency domain. 3.1. Cutting forces An evolution of the mean value of cutting forces over time at different feed rates at cutting speed 100 m/min is shown in Fig. 2. The forces are characterized by an increasing trend due to tool wear development. Feed components of cutting forces at the beginning of turning are similar independently on the lubrication strategy and cutting conditions. Components in cutting and passive directions differ quite much with increase of both feed rate and speed as well as lubrication. The increase
Oleksandr Gutnichenko et al. / Procedia CIRP 77 (2018) 437–440 Author name / Procedia CIRP 00 (2018) 000–000
of feed rate does not affect forces when using oil-GnP lubricant due to decreased friction in the cutting zone. Other lubrication strategies are characterized by a sensitivity of forces to cutting conditions where a feed has a considerable influence. The cooling/lubricating effect of pure oil on the force behavior (1025%) is more visible with increase of cutting speed. The utilization of GnP in MQL assisted machining results in the decrease in cutting forces up to 38%. 400
Fp
Ff;
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Fp
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F, N
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Fc;
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Fc;
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Fig. 4. Tool wear (a) dry; (b) MQCL oil; (c) MQCL oil-GnP.
200 100
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c) 0 0
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t, sec
The dependencies of wear on the flank face of the tool on the test conditions are shown in Fig. 5.
Fc MQLGr Ff MQLGr Fp MQLGr;
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b)
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100 50 0 0.0
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Fc MQL; Ff MQL; Fp MQL;
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Fc DRY; Ff FRY; Fp DRY;
200
5 0.08
0.125 f, mm/rev
0.16
c)
0
0.08
0.125 f, mm/rev
0.16
Fig. 3. Force variation (a) vc = 60 m/min; (b) 80 m/min; (c) 100 m/min.
Results show a significant difference in the force variation when lubricating with original oil and may imply a difference in tool wear development as compared to other lubrication strategies. An application of GnP shows comparable or less F values at low and moderate speeds and feed rates. Since the force variation value depends on processes in the cutting zone such as adhesion and friction on the rake and flank, chip segment formation and tool wear, a consideration of tool wear specifics at different lubrication strategies is quite important. 3.2. Tool wear SEM images of worn cutting edges at vc = 60 m/min and f = 0.125 mm/rev at dry, oil and GnP-oil lubrication conditions are shown in Fig. 4. Machining with GnP-oil lubrication is characterised by a maximum crater formation on the rake – white spot is a base CC material – that is, evidently, related to a higher contact pressure on the cutting edge due to the less contact area – red line. In general, the worn area also contains a delamination and damage of coating, chipping of the cutting edge, flaking and notch formation near h1min and h1max areas. The areas with a lack of coating is partially filled in with a workpiece material. More detailed analysis has shown that the damage and delamination of coating and flaking on the rake face is caused by a plastic deformation of the cutting edge. This fact also explains the steep increase in passive component of cutting forces before the total tool damage [4]. The utilization of original oil for MQL lubrication (Fig. 4 b) shows better effect on a wear debris disposal and minimum of
DRY MQL MQL-Gr
vc = 60 m/min vc = 80 m/min vc = 100 m/min broken
0.5 1.0 Length of cut, m (x1000)
1.5
100 50 0 0.0
b)
vc = 60 m/min vc = 80 m/min vc = 100 m/min broken
DRY MQL MQL-Gr
0.2 0.4 0.6 0.8 Length of cut, m (x1000)
1.0
100 DRY MQL MQL-Gr
50 0 0.0
c)
vc = 60 m/min vc = 80 m/min vc = 100 m/min broken
0.2 0.4 0.6 Length of cut, m (x1000)
Fig. 5. Flank wear (VBmax) at (a) 0.08; (b) 0.125; (c) 0.16 mm/rev.
20
15
10 0
Fc MQLGr Ff MQLGr Fp MQLGr;
F, N
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a)
Fc MQL; Ff MQL; Fp MQL;
20
F, N
20
30
Fc DRY; Ff FRY; Fp DRY;
200
Fig. 5 shows that tool life quite good correlates with cutting forces behavior. Utilization of original oil has a comparable or better tool life at higher speeds and feed rates used. The application of GnP modified oil shows the improvement of tool life almost at all test conditions excepting the case at vc = 80 m/min and f = 0.08 mm/rev. The mentioned is probably related to a presence of chipbreaker that, in combination with a reduced contact area, results in a negative effect on tool life. The similar phenomenon occurs when machining with pure oil at the lowest feed rate (Fig. 5 a). 3.3. Process dynamics and stability Fig. 6 shows the evolution in time of RMS values of accelerations at different cutting conditions. 20
ac, DRY; ac, MQL; ac, MQL-Gr;
af, DRY; af, MQL; af, MQL-Gr;
40
RMS acc, g
25
Fc MQL; Ff MQL; Fp MQL;
F, N
30
Fc DRY; Ff FRY; Fp DRY;
Caldie, f = 0.16 mm/rev
200 VBmax, m
The average values of force variation around its mean value during the machining time at different cutting test conditions is shown in Fig. 3.
Caldie, f = 0.125 mm/rev
Caldie, f = 0.08 mm/rev
Fig. 2. Cutting forces at vc = 100 m/min (a) 0.08; (b) 0.125; (c) 0.16 mm/rev.
VBmax, m
Ff;
ac, DRY; ac, MQL; ac, MQL-Gr;
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f = 0.08 mm/rev
VBmax, m
Fc;
DRY MQL MQL-Gr
tool damage [3]. At the same time, GnP decreases the contact area and friction between rake and chips but causes the higher impact on the cutting edge.
F, N
400
439 3
RMS acc, g
10 200
400
600
800 t, sec
0
c) 0
200
400
600 t, sec
Fig. 6. Accelerations at vc = 80 m/min (a) 0.08; (b) 0.125; (c) 0.16 mm/rev.
Mean value of vibrations amplitude at different cutting and lubrication conditions are presented in Figure 7. The difference between RMS values of accelerations is little at lower feed rate. Considering a similar behavior of mean values of cutting forces (Fig. 2) and their variations (Fig. 3) this may imply the similarity in dynamic interaction between tool, workpiece and processes in cutting zone. The increase of cutting speed and feed rate to 0.125 mm/rev results in significant increase of vibration intensity when machining with GnP-modified oil where the vibrations for dry turning and with pure oil are resemble. The increase of feed rate to 0.16 mm/rev and at higher cutting speeds leads to the 2-fold
Oleksandr Gutnichenko et al. / Procedia CIRP 77 (2018) 437–440 Author name / Procedia CIRP 00 (2018) 000–000
0.7
ac MQLGr af MQLGr
0.5 0.4 0.3 0.2 0.1 0.0
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a)
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ac DRY; af DRY;
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c)
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60 Power spectrum
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Power spectrum
Power spectrum
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a)
vc = 60 m/min
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2.5
50
MQL-GnP MQL DRY
2.5
0
8.4
14
18 24
29
18
5 10 15 20 25 30 35 40 45 f, kHz
Fig. 8. FFT of vibration signals (a) 60; (b) 80; (c) 100 m/min.
Low-frequency range (<12 kHz) includes three natural frequencies of tool holder 2.5, 3.2 and 8.2 kHz and vibrations of tool post and workpiece. High-frequency (above 12 kHz) – characterizes the adhesive and friction processes in the cutting zone and chips segmentation. FFT at low cutting speed showss a similarity of spectra for dry machining and with original oil one. The presence of GnP additives is determined by several harmonics next to one of the tool natural frequency (3.3-4.4 kHz) that is a result of reduced friction in the cutting zone leading to an increase of ‘effective process stiffness’. The increase of cutting speed shows the same behavior at low-frequency range. Segmentation frequency is concentrated at 25 kHz for all cases at cutting speed 80 m/min but spectra of MQL machining also show the generation of harmonics in higher frequency diapason 35-45 kHz (not shown in Fig. 8). FFT’s at maximum cutting speed demonstrate resemblance for dry and GnP-oil machining illustrating a strong excitation at 25 kHz – chip segmentation, as well as origin oil and GnPoil assisted machining at higher frequency range 35-40 kHz. This illustrates the ambivalent influence of GnP nanoadditives those, on the one hand, reduce friction between chip and tool rake and decrease a contact length of tool-chip interface, on the other, intensifies adhesive processes in the cutting zone. 3.4. Surface finish Independently on the physics behind the cutting process, the quality of the machined surface is one of the most important characteristics of the performance and define, in combination with other factors, an expediency of application of GnP for
2.0
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b)
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Lower values of cutting forces when turning with lubricants in combination with higher level of vibration, as compared to dry machining, implies the change of mechanisms occurring in a contact area: segment size; length, variation and regeneration of adhesion-friction zones on the rake; adhesion and friction on the flank. All these factors influence on the dynamics of the system and should be reflected in frequency domain. Fig. 8 shows FFT spectra of accelerations in cutting direction for a feed rate value f = 0.16 mm/rev at the beginning of the process. 3.3
2.0
1.5
0.3
Fig. 7. Vibration amplitude (a) 60; (b) 80; (c) 100 m/min.
3.0
DRY MQL MQL-Gr
Ra, m
ac MQL; af MQL;
Amplitude x 103, g
ac DRY; af DRY;
0.6
Amplitude x 103, g
Amplitude x 103, g
0.7
MQL assisted machining. Mean values of surface roughness (Ra) along a pass with error bars representing a deviation of the absolute value of Ra are shown in Fig. 9.
Ra, m
increase of vibration amplitude for both cases of lubrication with original and modified oils.
Ra, m
440 4
1.0 0.5
0.08 0.125 f, mm/rev
0.16
0.0
c)
0.08 0.125 f, mm/rev
0.16
Fig. 9. Surface finish at vc (a) 60 m/min; (b) 80; (c) 100 m/min.
Results show that Ra value when utilizing GnP-modified oil is very dependent on the amplitude of vibration (Fig. 7) and cutting conditions. As demonstrated low cutting speeds are not recommended to use due to the low surface quality (Fig. 9 a). The increase of the cutting speed shows quite comparable results for all cooling/lubrication strategies tested (Fig. 9 b, c). 4. Conclusions The following conclusions can be drawn for summarizing the results of the experiments and analyses: – GnP additives 0.2% (vol.) to vegetable oil are capable to significantly improve the process performance when MQCL assisted turning AHSS in terms of tool life, surface finish and process stability; – presence of GnP particles results in a significant reduction of friction in cutting zone in combination with cooling effect but inherit the influence of dry machining demonstrating higher adhesiveness at some cutting conditions that affects the surface finish. Acknowledgements This research is a part of “ECOnLub” research project funded by MISTRA Innovation Research Program in Product Innovation and Realization. It was also cofounded by the European Union’s Horizon 2020 Research and Innovation Program under the Flintstone 2020 project (grant agreement No 689279). The authors would like to thank SECO TOOLS AB, (Sweden) for support with tooling. Authors are also grateful to Mr. Milan Martinovic and Accu-Svenska AB (Sweden) for the support with MQCL system and consumables for the study. References [1] Pervaiz S., Rashid A., Deiab I., Nicolescu C.M. An experimental investigation on effect of minimum quantity cooling lubrication (MQCL) in machining titatium alloy (Ti6Al4V). International Journal of Advanced Manufacturing Technology2016; 87:1371–1386. [2] Boswell B., Islam M.N., Davies I.J., Ginting Y.R., Ong A.K. A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining. Int. J. Adv. Manuf. Technol. 2017; 92:321–340. [3] Chinchanikar S., Choudhury S.K. Hard turning using HiPIMS-coated carbide tools: Wear behavior under dry and minimum quantity lubrication (MQL). Measurement 2014; 55:536–548. [4] Nordgren A., Samani BZ., M´Saoubi R. Experimental Study and Modelling of Plastic Deformation of Cemented Carbide Tools in Turning. 6th CIRP International Conference on High Performance Cutting. Procedia CIRP 14 2014; 599–604