Machinability Evaluation in Hard Milling of AISI D2 Steel

Abstract

Milling of hardened steel components provides considerable benefits in terms of reduced manufacturing cost and time compared to traditional machining. Temperature variation in milling is an important factor affecting the wear of cutting tools. The poor selection of milling parameters may cause excessive tool wear and increased work surface roughness. Hence, there is a need to study the machinability aspects during milling of hardened steel components. In the present work, influence of cutting speed, feed rate and radial depth of cut on milling temperature, surface roughness and cutting force during milling of AISI D2 steel has been investigated using response surface methodology (RSM) based models. From the parametric analysis, it is revealed that temperature increases linearly, whereas surface roughness increases non-linearly with cutting speed. However, for higher values of feed rate, an increased cutting speed considerably reduces the cutting force for specified depth of cut range. The present work also reveals that the selection of best cutting conditions is useful at the CAPP stage in the milling process particularly with tight tolerances.

Experimental Milling Studies on Hardened Steels - A Review

“…Hard metals behave relatively different during machining processes. For example, tool steel X155CrVMo12-1 (AISI D2), which can have its hardness increased by heat treatment operations up to 62 HRC, has a very high resistance to mechanical shocks due to the presence of chromium in the microstructure, and the behaviour during machining operations for this type of alloy is similar to that of alloys with even higher hardnesses than this (Gaitonde et al, 2016). On the other hand, the alloy type X20Cr13 (AISI 420), which is a stainless steel but can be hardened up to 52 HRC, retains its stainless properties and tends to adhere to the clearance surface of cutting tools, generating the socalled Build-up edge (BUE).…”

Influence of feed direction on finishing milling cylindrical surfaces in H13 hardened steel

“…In this context, milling of steel in the hardened state provides substantial benefits in terms of reducing production Technical Editor: Lincoln Cardoso Brandão. time and manufacturing costs when compared to the traditional way [11,12].…”

Mathematical Modeling and Optimization of Milling Parameters in AA 5083 Aluminum Alloy

“…Fedai et al [15] used multi-objective Taguchi Technique to multi-response optimization of input variables on face milling of AISI 4140 steel with PVD TiAlN/TiN coated carbide inserts. Gaitonde et al [16] researched the effect of input parameters on cutting force, surface roughness and temperature in hard milling using RSM. Elkhabeery et al [17] investigated the influence of input variables on the surface roughness, cutting force and material removal rate of AA 5083 aluminum alloy in CNC end milling using RSM.…”