Preheating in End Milling of AISI D2 Hardened Steel with Coated Carbide Inserts

Abstract:

This study was conducted to investigate the effect of preheating through inductive heating mechanism in end milling of AISI D2 hardened steel (60-62 HRC) by using coated carbide tool inserts. Apart from preheating, two other machining parameters such as cutting speed and feed were varied while the depth of cut constant was kept constant. Tool wear phenomenon and machined surface finish were found to be significantly affected by preheating temperature and other two variables. End milling operation was performed on a Vertical Machining Centre (VMC). Preheating of the work material to a higher temperature range resulted in a noticeable reduction in tool wear rate leading to a longer tool life. In addition, improved surface finish was obtained with surface roughness values lower than 0.4 μm, leaving a possibility of skipping the grinding and polishing operations for certain applications.

• Periodical: Advanced Materials Research (Volumes 83-86)
• Pages: 56-66
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.83-86.56
• Online since: December 2009
• Authors: Mohd Amri Lajis, A.K.M. Nurul Amin, A.N. Mustafizul Karim, A.M.K. Hafiz
• Keywords: Hardened Steel, Preheated Machining, Surface Roughness (SR), Tool Wear

References

[1] P. Koshy, R.C. Dewes, D.K. Aspinwall, High speed end milling of hardened AISI D2 tool steel (58 HRC), Journal of Materials Processing Technology 127 (2002), 266-273.

DOI: 10.1016/s0924-0136(02)00155-3

[2] K.P. Maity, P.K. Swain, An experimental investigation of hot-machining to predict tool life, Journal of Materials Processing Technology (2007).

[3] P. Dumitrescu, P. Koshy, J. Stenekes, M.A. Elbestawi, High-power diode laser assisted hard turning of AISI D2 tool steel, Int. Journal of Machine Tools & Manufacture (2006).

DOI: 10.1016/j.ijmachtools.2006.01.005

[4] S. Tour, L.S. Fletcher, Hot spot machining, Iron Age (78), 164.

[5] E.T. Armastrong, A.S. Closer, E.F. Kate, Machining of heated metals, ASME 35 (1951), 73.

[6] E.J. Krabacher, M.E. Merchant, Basic factors in hot machining of metals, Trans. ASME 73 (1951), 761.

DOI: 10.1115/1.4016424

[7] A.O. Schmidt, H.R. Roubik, Milling hot work piece, Eng. Dig. 10 (1949).

[8] G. Barrow, Machining at high strength metals at elevated temperature using electrical current heating, Annals of CIRP 14 (1966), 145-151.

[9] L. Ozler, A. Inan, C. Ozel, Theoretical and experimental determination of tool life in hot machining of austenitic manganese steel, Int. Journal of Machine Tools & Manufacture 41 (2006), 163-172.

DOI: 10.1016/s0890-6955(00)00077-8

[10] A.K.M.N. Amin, S.B. Dolah, M.B. Mahmud, M.A. Lajis, Effects of workpiece preheating on surface roughness, chatter and tool performance during end milling of hardened steel D2, Journal of Materials Processing Technology 201 (2008), 466-470.

DOI: 10.1016/j.jmatprotec.2007.11.304

[11] M.M. Abdelgadir, The effect of preheating of work material on chatter of VMC and machinability of work materials, Masters Dissertation International Islamic University Malaysia (2001).

[12] A.K.M.N. Amin, M.M. Abdelgadir, The effect of preheating of work material on chatter during end milling of medium carbon steel performed on a vertical machining center (VMC), ASME Journal of Manufacturing Science and Engineering (2003), 674-680.

DOI: 10.1115/1.1596557

[13] A.K.M. N Amin, I. Abraham, N. Khairussima, Influence of preheating on the performance of circular carbide inserts in end milling of carbon steel, Proceedings of the 3rd International Conference on Advanced Manufacturing Technology ICAMT, Kuala Lumpur (2004).

DOI: 10.1016/j.jmatprotec.2006.03.131

[14] Marlina Mahmud and Shuriani Dolah, Influence of preheating on chatter and machinability of hardened sSteel AISI D2 in end milling, Undergraduate Thesis Kuliyyah of Engineering IIUM Kuala Lumpur (2005).

[15] H.Z. Li, H. Zeng, X.Q. Chen, An experimental study of tool wear and cutting force variation in the end milling of inconel 718 with coated carbide inserts, Journal of Material Processing Technology 180 (2006), 296-304.

DOI: 10.1016/j.jmatprotec.2006.07.009

[16] Reed-Hill, Robert, Principles of Physical Metallurgy, PWS Publishing, 3rd edition, Boston (1994).

[17] C.E. Becze, M.J. Worswick, M.A. Elbestawi, High strain rate shear evaluation and characterization of AISI D2 tool steel in its hardened state, Machining Science and Technology 5 (2001), 131-149.

DOI: 10.1081/mst-100103182