Reducing Tool Wear with Hybrid Microwave Treated TiCN Coated Tool and Recycled Cooking Oil in MQL Machining of T6061 Aluminium Alloy

Titanium carbo-nitride (TiCN) inserts are vital for cutting operations, particularly in high-temperature conditions. Conventional machining methods lead to rapid wear of tools, frequent need for tool changes, high costs associated with tool replacement, and extensive usage of synthetic cutting fl uids that are environmentally damaging. This study aims to minimise tool wear and promote circular economy. This study examines the process of machining T6061 aluminium alloy using TiCN inserts treated with hybrid microwave (HMW) energy at 220℃ for 20 minutes, with silicon dioxide (SiO2) as the susceptor. Recycled cooking oil is utilised for Minimum Quantity Lubrication (MQL). Analysed were the density, hardness, and microstructural images. Tool wear of TiCN was assessed during dry and wet machining using three different cutting speeds (166, 210, 263 m/min) while maintaining a constant feed rate of 0.6mm/rev and depth-of-cut of 0.4 mm. The findings show the density and hardness of TiCN (HMW) increased by 4% and 7% respectively compared to the TiCN (untreated) insert. The tool wear of TiCN (HMW) has reduced by 5% (MQL) and 24% (dry) compared to the TiCN (untreated) insert. MQL with recycled cooking oil decreased tool wear by 40% compared to dry machining. The microstructural images of the TiCN (HMW) and TiCN (untreated) structures reveal no noticeable variations. TiCN (HMW) has improved wear resistance, and it is particularly beneficial when utilising recycled cooking oil in MQL machining.