Optimization of Machining Parameters in AISI 304 Stainless Steel Using Response Surface Methodology

The machining of difficult-to-cut materials, such as stainless steel, titanium alloys, and Inconel, poses significant challenges due to their high strength, low thermal conductivity, and work-hardening tendencies. These challenges result in increased cutting forces, rapid tool wear, and poor surface quality. To enhance machining performance while promoting sustainability, this study investigates the use of brass nano-cutting fluid in Minimum Quantity Lubrication (MQL) techniques. Brass nanoparticles, known for their excellent thermal conductivity, corrosion resistance, and antifriction properties, improve lubrication and heat dissipation, leading to reduced tool wear and enhanced surface finish. The experimental setup involves turning operations on AISI 304 stainless steel using uncoated cemented carbide tools. Key response parameters, such as material removal rate, temperature at the cutting zone, and surface roughness, are examined to determine the effectiveness of brass nano-cutting fluid in optimizing machining outcomes. Results from ANOVA and regression models reveal that the depth of cut and feed rate significantly influence machining performance. The integration of brass nanoparticles in MQL not only enhances efficiency but also aligns with sustainable manufacturing principles by reducing fluid consumption and environmental impact. The optimization of the additive ratio of brass nanoparticles provided better outcomes identified in the range of 2-10g with 200 ml of cutting fluid. This study provides valuable insights into the potential of brass nano-cutting fluids in advancing modern machining processes.