Experimental investigation on performance of bubble-bursting atomization methods for minimum quantity lubrication in face milling tool steel

The metal cutting industry faces challenges in machining hard materials due to high forces and temperatures. This paper introduces bubble-bursting atomization minimum quantity lubrication (BBA-MQL), a novel MQL technique that generates fine biodegradable oil mists for cooling and lubrication. Although the initial results of BBA-MQL are promising, there has not been a comprehensive investigation into its use in machining hard materials, specifically tool steels. Therefore, this study focused on the applicability of BBA-MQL in face milling of AISI P20 + Ni tool steel in comparison with dry cutting and conventional MQL using commercial and vegetable oil. The machining tests were performed at three cutting speeds (50, 80, and 110 m/min), fixed cutting depth (0.2 mm), and feed rate (0.15 mm/tooth). The performance is evaluated by measuring the cutting force, surface quality, cutting temperature, and tool wear. It was found that BBA-MQL decreased cutting force and surface roughness considerably, with the average reductions being 23.2 % and 49.8 % compared with the conventional minimum quantity lubrication. The highest cutting speed of 110 m/min was preferred for achieving the lowest roughness value and cutting force when milling tool steel P20 + Ni. Furthermore, BBA-MQL with castor oil proved more effective compared to conventional MQL in reducing cutting force, showing improved surface finish, reduced cutting temperature, and delayed tool wear. • The performance of bubble-bursting atomization MQL for milling process techniques has been examined. • AISI P20 + Ni tool steel machinability was tested under dry, MQL, and BBA-MQL with commercial and castor oils. • Performance criteria investigated were cutting force, surface roughness and topography, cutting temperature, and tool wear. • The best performance was BBA-MQL with the castor oil lubrication technique.