Effect of magnetorheological fluid on tool wear during hard turning with minimal fluid application

Tool wear is a very complex phenomenon which can lead to machine down time, product rejects and can also cause problems to personnel. The present investigation aims at developing a magnetorheological fluid setup that can be attached to the tool holder for reducing tool wear during hard turning with minimal fluid application. The magnetorheological fluid acts as a viscoelastic spring with non-linear vibration characteristics that are controlled by parameters like the viscosity index of the fluid medium, shape of the plunger, current through the coil and size of the ferromagnetic particles. Cutting experiments were conducted to arrive at a set of magnetorheological fluid parameters that can offer better damping characteristics to minimize tool wear and promoting better cutting performance during turning of AISI 4340 steel of 46 HRC with minimal fluid application using hard metal insert with sculptured rake face. From the results, it was observed that the presence of magnetorheological fluid setup during hard turning with minimal fluid application attached to the tool holder reduces tool wear and brought forth better cutting performance. Commercialization of this idea is sure to benefit the metal cutting industry.