Micro-Milling of Hardened AISI D2 Tool Steel

Abstract:

The paper presents an experimental investigation into the slotting of hardened AISI D2 (~62HRC) tool steel using 0.5mm diameter coated (TiAlN) tungsten carbide (WC) end mills. SEM analysis of tool morphology and coating integrity was undertaken on all tools prior to testing. Tool wear details are given based on resulting cutter diameter and slot width reduction. In addition, cutting forces are also presented together with details of workpiece burr formation. A full factorial experimental design was used with variation of cutting speed, feed rate and depth of cut, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on microscale milling best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors. Cutting speed was shown to have the greatest effect on tool wear (33% PCR). When operating at 50m/min cutting speed with a feed rate of 8µm/rev and a depth of cut of 55µm, cutter diameter showed a reduction of up to 82µm for a 520mm cut length. SEM micrographs of tool wear highlighted chipping / fracture as the primary wear mode with adhered workpiece material causing further attritious wear when machining was continued up to 2.6m cut length. All tests produced burrs on the top edges of the slots which varied in size / width to a lesser or greater degree. Under the most severe operating conditions, burr width varied from approximately 50µm to more than 220µm over the 520mm cut length. Cutting forces in general were less than 12N up to test cessation.

• Periodical: Advanced Materials Research (Volume 445)
• Pages: 62-67
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.445.62
• Online since: January 2012
• Authors: J.B. Saedon, S.L. Soo, D.K. Aspinwall, A. Barnacle
• Keywords: Machinability, Micro-Milling, Tool Wear

References

[1] P. Rodriguez, in: Proceedings of ECTC 2008, ASME Early Career Technical Conference, Miami, USA (2008), p.1.

[2] M. Rahman, A.S. Kumar and J.R.S. Prakash: J. Mater. Process. Technol. Vol. 116 (2001), p.39.

[3] S. Filiz, C.M. Conley, M.B. Wasserman and O.B. Ozdoganlar: Int. J. Mach. Tools Manuf. Vol. 47(7) (2007), p.1088.

[4] Rusnaldy, T.J. Ko and H.S. Kim: Int. J. Mach. Tools Manuf. Vol. 47(14) (2007), p.2111.

[5] K. Weinert and V. Petzoldt: Mater. Sci. Eng. A Vol. 481-482 (2008), p.672.

[6] E. Uhlmann, S. Piltz and K. Schauer: J. Mater. Process. Technol. Vol. 167 (2005), p.402.

[7] P. Li, A.M. Hoogstrate, J.A.J. Oosterling, H.H. Langen and R.M. Schmidt, in: Proceedings of the 3rd International CIRP High Performance Cutting Conference, Dublin, Ireland (2008), p.69.

[8] A. Aramcharoen and P.T. Mativenga: Precis. Eng. Vol. 33(4) (2009), p.402.

[9] G. Bissacco, H.N. Hansen and L. De Chiffre: J. Mater. Process. Technol. Vol. 167 (2005), p.201.

[10] K. Lee and D.A. Dornfeld: Precis. Eng. Vol. 29(2) (2005), p.246.

[11] H. Li, X. Lai, C. Li, J. Feng and J. Ni: J. Micromech. Microeng., Vol. 18 (2008), p.1.

[12] I. Tansel, O. Rodriguez, M. Trujilo, E. Paz and W. Li: Int. J. Mach. Tools Manuf. Vol. 38(12) (1998), p.1419.

[13] P. Li, J.A.J. Oosterling and A.M. Hoogstrate, in: Proceedings of the 2nd International Conference on Micromanufacturing, Greenville, USA (2007), p.219.

[14] T. Lawrenson, Undergraduate Project Report, University of Birmingham. (2008).

[15] Z.J. Cheng, S.K. Ik, H.P. Jin, H.J. Su and S.K. Jeong: J. Mech. Sci. Technol. Vol. 23(10) (2009), p.2823.