Investigation on Surface Integrity in Hard Turning of AISI 4140 Steel with SPPP-AlTiSiN Coated Carbide Insert under Nano-MQL

The machined surface integrity in the turning of hardened steels is adversely influenced by heat generation and friction which requires pacification temperature effective cooling-lubrication approach cutting tool performance. present research analyzes AISI 4140 steel during with recently developed scalable pulsed power plasma SPPP-AlTiSiN coated carbide under nanofluid-assisted minimum quantity lubrication (MQL). Zinc oxide nanoparticles environmentally friendly radiator coolant are mixed to prepare nano fluid. This analysis addresses various aspects concerning morphology, hardness, residual stress white layer development, finish varying parameters (depth cut, speed, feed, nose radius). Response methodology (RSM) suggested predict optimize roughness hard turning. Thereafter, predictive modelling optimization results implemented for economic analysis. According findings experiments, a contribution 58.18%, feed rate possesses high impact on finish, followed radius (12.32%) speed (0.85%). Consequently, quality improved increase because wear due length edge. At optimum conditions, life insert noted as 46 minutes nanofluid-MQL consequently, it estimated overall machining cost per component Rs.23.12 Indian currency.