The purpose of this study was to investigate and establish the correlations between milling tool geometry, cutting conditions, as input factors and the cutting forces variations and chips formation, as output factors when end milling of AISI D2 tool steel. The experiments were carried out using a Taguchi design array. The chip shape and microstructure and cutting force components were analyzed. The results of the study show that the cutting tool geometry has a great influence over segmented chip formation mechanism and cutting force levels.
Analysis of chip formation and cutting forces in end milling AISI D2 tool steel with different cutting tool geometries