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Tool Wear Effect on Machinability and Surface Integrity in MQL and Cryogenic Hard Turning of AISI 4340.

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Title: Tool Wear Effect on Machinability and Surface Integrity in MQL and Cryogenic Hard Turning of AISI 4340.
Authors: Jouini, Nabil1 (AUTHOR) n.jouini@psau.edu.sa, Yaqoob, Saima2,3 (AUTHOR), Ghani, Jaharah A.2,3 (AUTHOR), Mehrez, Sadok1 (AUTHOR)
Source: Materials (1996-1944). Dec2025, Vol. 18 Issue 23, p5423. 16p.
Subjects: Carbide cutting tools, Machining, Low temperature engineering, Surface finishing, Lubrication systems, Steel alloys, Abrasive machining
Abstract: Hard turning has emerged as a cost-effective and flexible alternative to conventional grinding for machining hardened steels such as AISI 4340. However, its performance is significantly influenced by the choice of cooling and lubrication strategies, as well as the condition of the cutting tool. Inadequate thermal management and tool wear can lead to elevated cutting forces, high interface temperatures, degraded surface quality, and an altered microstructure. This study investigates the machinability performance of AISI 4340 alloy steel (50 HRC) using CVD-coated carbide tools under two distinct cooling/lubrication environments: minimum quantity lubrication (MQL) and cryogenic cooling (LN2). Experiments were conducted at the beginning and end of tool life with both environments to capture the influence of tool wear on key performance indicators, including cutting force, chip temperature, surface roughness, and microstructural integrity. Results indicate that LN2 cooling outperformed MQL in mitigating thermal loads and maintaining surface quality, particularly under worn tool conditions. LN2 reduced cutting forces by up to 37.10%, chip temperature by 56.68%, and surface roughness by 36.95% compared to MQL. Microstructural analysis revealed significantly thinner deformation and white layers under LN2, suggesting improved subsurface integrity. These findings highlight the potential of LN2 cooling for enhancing the machinability of hard turning operation and improving overall performance in industrial applications. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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Header DbId: egs
DbLabel: Engineering Source
An: 190517572
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Tool Wear Effect on Machinability and Surface Integrity in MQL and Cryogenic Hard Turning of AISI 4340.
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  Data: <searchLink fieldCode="AR" term="%22Jouini%2C+Nabil%22">Jouini, Nabil</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> n.jouini@psau.edu.sa</i><br /><searchLink fieldCode="AR" term="%22Yaqoob%2C+Saima%22">Yaqoob, Saima</searchLink><relatesTo>2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ghani%2C+Jaharah+A%2E%22">Ghani, Jaharah A.</searchLink><relatesTo>2,3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mehrez%2C+Sadok%22">Mehrez, Sadok</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Dec2025, Vol. 18 Issue 23, p5423. 16p.
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22Carbide+cutting+tools%22">Carbide cutting tools</searchLink><br /><searchLink fieldCode="DE" term="%22Machining%22">Machining</searchLink><br /><searchLink fieldCode="DE" term="%22Low+temperature+engineering%22">Low temperature engineering</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+finishing%22">Surface finishing</searchLink><br /><searchLink fieldCode="DE" term="%22Lubrication+systems%22">Lubrication systems</searchLink><br /><searchLink fieldCode="DE" term="%22Steel+alloys%22">Steel alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Abrasive+machining%22">Abrasive machining</searchLink>
– Name: Abstract
  Label: Abstract
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  Data: Hard turning has emerged as a cost-effective and flexible alternative to conventional grinding for machining hardened steels such as AISI 4340. However, its performance is significantly influenced by the choice of cooling and lubrication strategies, as well as the condition of the cutting tool. Inadequate thermal management and tool wear can lead to elevated cutting forces, high interface temperatures, degraded surface quality, and an altered microstructure. This study investigates the machinability performance of AISI 4340 alloy steel (50 HRC) using CVD-coated carbide tools under two distinct cooling/lubrication environments: minimum quantity lubrication (MQL) and cryogenic cooling (LN2). Experiments were conducted at the beginning and end of tool life with both environments to capture the influence of tool wear on key performance indicators, including cutting force, chip temperature, surface roughness, and microstructural integrity. Results indicate that LN2 cooling outperformed MQL in mitigating thermal loads and maintaining surface quality, particularly under worn tool conditions. LN2 reduced cutting forces by up to 37.10%, chip temperature by 56.68%, and surface roughness by 36.95% compared to MQL. Microstructural analysis revealed significantly thinner deformation and white layers under LN2, suggesting improved subsurface integrity. These findings highlight the potential of LN2 cooling for enhancing the machinability of hard turning operation and improving overall performance in industrial applications. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.3390/ma18235423
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      – Code: eng
        Text: English
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        StartPage: 5423
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        Type: general
      – SubjectFull: Machining
        Type: general
      – SubjectFull: Low temperature engineering
        Type: general
      – SubjectFull: Surface finishing
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      – SubjectFull: Lubrication systems
        Type: general
      – SubjectFull: Steel alloys
        Type: general
      – SubjectFull: Abrasive machining
        Type: general
    Titles:
      – TitleFull: Tool Wear Effect on Machinability and Surface Integrity in MQL and Cryogenic Hard Turning of AISI 4340.
        Type: main
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          Name:
            NameFull: Jouini, Nabil
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            NameFull: Yaqoob, Saima
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            NameFull: Ghani, Jaharah A.
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            NameFull: Mehrez, Sadok
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            – D: 01
              M: 12
              Text: Dec2025
              Type: published
              Y: 2025
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              Value: 23
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            – TitleFull: Materials (1996-1944)
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