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ABSTRACT
This work presents a series of experimental investigations and corresponding theoretical analyses to research on the effect of cryogenic minimum quantity lubrication (MQL) on machinability of diamond tool in ultraprecision turning of typical die steel. The tool wear and machined surface quality were determined as experimental indexes, which were measured using the scanning electron microscope and surface profiler, respectively. Besides, the maximum temperatures of diamond tool surfaces acquired by infrared thermal imager were used to indirectly evaluate the cutting process. The experimental results revealed that cryogenic MQL had obvious advantages in improving diamond tool durability and machined surface quality by comparison with flood cooling, cryogenic gas cooling, and MQL, and its essential function mechanisms were thoroughly understood. On the basis of this, carbon nanofluid was found to achieve optimal tool life in diamond turning compared with polyethylene glycol, castor oil, synthetic ester, and emulsified liquid. Ultimately, the combined machining method of ultrasonic vibration-assisted turning and cryogenic minimal quantity lubrication was proposed in this work. The results showed that this technique could observably improve the machinability of diamond tool and also provide a new direction for exploring a suitable processing method for ultraprecision machining of ferrous materials.