Enhancing AISI D2 Steel Milling: Balancing Surface Quality and Tool Life

Abstract

The aspects of cutting tool life and the quality of machined workpiece surfaces are pivotal considerations within field of machining processes. While a thorough review of the existing literature has revealed a multitude of investigations about the milling of steels frequently employed in cold work tool manufacturing, there is a conspicuous lack of experimental studies that have effectively determined the optimal values for cutting speed and feed. This determination is imperative to ensure the concurrent minimization of surface roughness and maximization of the tool life. Hence, the primary objective of this research endeavor is to discern the most finely tuned parameters conducive to milling AISI D2 steel with a milling cutter equipped with GC1130 coated inserts to optimize the interdependent variables. The analytical process demanded the development of multiple regression models, the validity of which was assess through an examination of residual graphs. Also, an analysis of variance was conduct, shedding light on their individual and collective impacts. Besides, the relationship between the cutting parameters and the resultant output factors was meticulously examine through the employment of response surface plots. The quest for a multi-faceted optimization solution, the desirability technique was harness. In summary, the comprehensive analysis conducted in this study substantiates the assertion that a judiciously selected combination of low cutting speed and high feed rate has a pronounced positive impact on the specified output variables. This collective enhancement attains an admirable level of desirability, reflecting both acceptable and excellent outcomes across the myriad facets of the milling operation.