Hybridization of two or more such processes is very much capable to achieve the goal of sustainability. Sustainability in the machining process can be achieved by promoting environmental friendly practices such as dry machining, gas-cooled machining, near dry machining using minimum quantity lubrication, cryogenic cooling, ionic fluids, biodegradable and eco-friendly cutting fluids, etc. Sustainable machining is defined as the creation of products by cutting material that uses the processes which are environmental friendly, economically sound and safe for employees, consumers and communities as well as can conserve energy. Advances in sustainable machining are a subset of sustainable manufacturing. To support and promote such initiatives, researchers, scientists, engineers and academic institutions have a responsibility to introduce educational programs related to sustainable manufacturing to prepare the future generation. Recently, governments and world leaders are advocating for sustainable manufacturing initiatives. Sustainability in any organization implies that something can be sustained indefinitely. The ever increasing trends of the upcoming technology also lead to many concerns related to environment, society and economics in every field of engineering. The outcomes are expected to find applicability in all sectors of the metal cutting industry, which are striving for elongations in tool life and improvements in work surface quality The presented work is novel as it presents a new approach to extend the working life of cutting tools without compromising the other sustainability measures. For the experimental work reported herein, the surface-quality based tool life criterion yielded on average 23% longer tool life. Finally, it is concluded that a tool life criterion based on work surface roughness can yield longer tool life values and make the machining process more sustainable. Being more economical in respect of acquisition cost than the CBN inserts and more effective than the uncoated carbide inserts regarding tool life, the coated carbide inserts came out as the most sustainable tooling option. Overall, the CBN inserts yielded the longest tool life values, especially at high levels of cutting speed. It is found that different combinations of tooling and cutting parameters lead to entirely different values of surface roughness at the same level of flank wear, thus raising the possibility of extending the working life of the tools. The proof of the concept is provided by a series of face-turning experiments performed on a commonly used alloy steel using the following cutting inserts in dry conditions: (1) uncoated carbide (2) coated carbide and (3) cubic boron nitride (CBN). This work puts forward a tool life criterion based on the surface quality of the machined part. The very question that serves as the motivation for this work is, “why should tool life criterion be based on the shape of the tool when all that matters for business is the quality of the part being machined?”. From this perspective, limiting the working life of a cutting tool based merely on the blunting of its cutting edge to a specific value is highly questionable. Extending the use of a component without compromising its intended functionality is the neatest approach to enhance sustainability.
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