Metal cutting operation results in generation of high friction, causing increased production of heat in cutting area. The above problem can be solved by utilizing the combination of bio-mimicked structured tools and nano-green cutting oil under minimum quantity lubrication (MQL) conditions. Therefore an experimental study was conducted to examine the influence of nano-green machining oil (sunflower oil + hBN nanoparticles) and green cutting oil (sunflower oil) using bio-mimicked flank and rake face crescent structured tools for sustainable machining of hard-to-machine AISI 420 material under MQL environments. The experiments were carried out at depth (
ap) = 0.3 mm, cutting velocity (
vc) = 315 m/min, and feed (
fz) varied at four levels (0.08, 0.112, 0.16, 0.20) mm/rev. The study indicated that (MQL + NP) structured tool outperformed machining performances relative to the dry structured tool. Adhesion and abrasion are the most frequent types of wear noticed on the cutting tool. The results indicate an average reduction of 28.12, 17.47, 17.24, 20.85, and 17.36% in the average flank wear, specific energy consumption, average surface roughness, feed force, and tangential force relative to dry structured tools. Segmented chips are formed under all lubrication conditions, and the chip formed using (MQL + NP) structured tool demonstrated a minimum chip reduction coefficient of 1.54 and a highest segmentation ratio of 0.298, indicating favorable machining operation. The research insights are beneficial for the application of bio-mimicked structures in different lubrication conditions.
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