Performance characteristics of hardened AISI D2 steel turning: A review Rajashree Mallick, Ramanuj Kumar ⇑ , Amlana Panda, Ashok Kumar Sahoo KIIT Deemed to be University, Bhubaneswar, Odisha 751024, India article info Article history: Received 20 January 2020 Accepted 14 February 2020 Available online xxxx Keywords: Hard turning D2 steel Cutting tool Cooling techniques Tool life Surface roughness abstract Hard turning is the process of machining hardened steels that have above 45HRC. In metal- manufacturing, hard turning potentially substitutes the grinding process as it possesses lots of benefits like higher metal volume removal rate, less costly, easy to handle, flexible tooling and exhibiting closer surface quality to grinding finish. In the current scenario, plenty of works were reported on hard turning on AISI D2 steel. As hardened D2 steel is popularly used in Die-Punch, Press-tool making industries, auto- mobile industries etc. However, it is worth needed to briefly summarize all the works published on the hard turning of D2 steel. This will provide a platform for the machinist, industrialist, and researchers to further precede their work on D2 steel. In this review work, basically performance characteristics were discussed considering different cutting tools, distinguish coolants and cooling methodologies aspects. MQL works well in hard D2 turning; however, a combination of different coolants like nanofluid, ionic fluid can be utilized in the future. SIC cooling also provides promising results hence it needs to be elab- orated more considering different coolants. Also, force and tool condition monitoring can be studied in hard D2 turning using the SIC technique. Ó 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 10th International Con- ference of Materials Processing and Characterization. 1. Introduction Machining is the utmost flexible unwanted-material removal technique, which attributed the desired size, shape and surface fin- ish. Nowadays, major objectives of industries are to increase pro- ductivity with balanced quality of finish at minimal energy consumption, which in turn lead to economic and eco-friendly manufacturing. Various machining operations such as milling, turning to grind are popularly utilized in industry to get the desired precise product. For a high quantity of demand, turning is more favorable than grinding of hard metal. However, hard turn- ing refers to the process of machining where a single point cutting tool is utilized to machine the cylindrical-shaped job of hardness beyond 45 HRC [1]. Hard turning attributes reasonable surface fin- ish with elevated dimensional-accuracy and desired shape. Some primary advantages of hard turning were higher material removal rate, short set-up time, better surface texture, lower machining cycle with minimal production cost. The D2 steel comprises of carbon (1.53%), chromium (11.5%), molybdenum (0.72%), vanadium (0.95%), silicon (0.26%), and man- ganese (0.28%) by weight [2]. As % of alloying elements like chro- mium and carbon are highest, hence it is popularly known as high chromium and high carbon cold tool steel. Hardened D2 steel (55–62 HRC) possesses excellent wear and abrasion resistance, due to the existence of large quantities of carbides in the microstruc- ture, which makes its suitability as a material for die making, knife making, press tool, and automobile industries. Due to higher hard- ness, its machining comes in the category of difficult to machine. Due to growth in tooling technology, many types of inserts were developed and utilized till date to machine the heat-treated tool steel. CBN, Ceramic, coated CBN, coated ceramic etc. were popu- larly accepted in dry hard turning but due to higher tooling cost of CBN or coated CBN and difficult to handle the ceramic insert (due to highly brittle in nature) their use is prohibited [3]. Further, cheaper tool like multi layered coated carbide insert was devel- oped for the hard turning. But due to immense amount of cutting heat developed in dry turning, tool-wear rate is prominent, how- ever to minimize the cutting heat, different cooling technology and distinguish coolant were used. However, in the field of hard metal machining, currently researchers are giving emphasis on selection of best combination of cooling technology and coolant. In the process of hard turning, the turning tool is subjected to severe mechanical and thermal stresses which attributed the https://doi.org/10.1016/j.matpr.2020.02.565 2214-7853/Ó 2020 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 10th International Conference of Materials Processing and Characterization. ⇑ Corresponding author. E-mail address: ramanujkumar22@gmail.com (R. Kumar). Materials Today: Proceedings xxx (xxxx) xxx Contents lists available at ScienceDirect Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr Please cite this article as: R. Mallick, R. Kumar, A. Panda et al., Performance characteristics of hardened AISI D2 steel turning: A review, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.02.565