Enhancing Al6061 alloy machinability in turning operations through RHVT, MQL and textured tool integration

Purpose This study aims to explore eco-friendly/sustainable machining methods that are cost-effective, capable of conserving energy and have minimal harmful effects on human health as well as the environment. Design/methodology/approach This study is concerned with turning of aluminum alloy Al6061 with an application of varying methods, i.e. dry turning, MQL turning, the use of Ranque–Hilsch Vortex tube (RHVT), accompanied by minimum quantity lubrication (MQL) with textured tool. Parallel texture patterns provided sufficient lubrication to the tool while using combined RHVT and MQL techniques. Canola oil, because of its excellent lubricating/cooling action, was used as cutting oil in the MQL system. Tangential cutting force (Ft), temperature at the tool tip and average surface roughness (Ra) were selected as output parameters to measure turning performance. Findings At a higher cutting speed of 160 m/min. and low feed rate of 0.2 mm/rev, Ra decreased by (10.2%, 16.2%, 29.5%) and Ft reduced by (6.7%, 13%, 30.7%) when compared with dry turning using plain insert (S1), under MQL system with textured insert (S2), MQL+RHVT system using plain insert (S3) and MQL+ RHVT system using textured insert (S4). The temperature decrement under all the machining conditions with cutting speed and feed rate variation lies in the order of S1S2S3S4. RHVT and MQL with a textured tool significantly reduced the cutting temperature because of ample cooling as well as lubrication at the cutting zone in comparison to all other tested cases. Practical implications Using sustainable methods can be explored in the conventional turning industry to enhance the machine’s performance and minimize the harmful implications on human health as well as the environment. Originality/value Very few researchers used chilled air from RHVT along with a textured tool during turning. RHVT cooling technique is in demand at the time to lower down the cutting temperature with chilled air along with an MQL system to decrease surface roughness and cutting forces during turning.