Surface Integrity in Hot Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 500 ◽  
pp. 44-50 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim
Keyword(s):  
Induction Heating ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Heating Temperature ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Aisi D2 ◽  
Hot Machining ◽  
Coated Carbide

This study presents experimental results of machined surface integrity of die material (AISI D2 hardened steel) when hot machining (induction heating) assisted end milling using coated carbide is applied. The aim of this work was to study the influence of induction heating temperature, cutting speed, and feed on the effects induced by hard milling on surface integrity (microhardness and work-hardening). Microhardness was measured to observe the distribution of the hardness beneath the surface and to determine the effect of induction heating on the micro-hardness distribution and work-hardening phenomena. The behaviour of microhardness induced in the subsurface region when end milling under room and induction heating cutting conditions using coated carbide inserts was also investigated. The surface integrity and subsurface alteration have been investigated by employing scanning electron microscope (SEM) and Vickers microhardness tester.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

scholarly journals Keutuhan Permukaan Bahan Keluli Perkakas Setelah Pengisaran Hujung Menggunakan Perkakas Karbida Bersalut

2012 ◽  
Author(s):  
Che Hassan Che Haron ◽  
Andanastuti Muchtar ◽  
Nik Faizu Nik Kundor
Keyword(s):  
Tool Steel ◽  
Surface Integrity ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Machined Surface ◽  
Aisi D2 ◽  
Coated Carbide

Projek ini dijalankan bertujuan untuk mengkaji kesan proses pengisaran terhadap keutuhan permukaan keluli perkakas D2. Dalam kajian ini, keluli perkakas kerja sejuk AISI D2 yang telah dikeraskan kepada 62 HRC dimesin menggunakan sisip karbida bersalut CVD boleh indeks yang dipegang oleh perkakas pengisaran hujung berdiameter 20 mm. Siri–siri ujian dijalankan dalam keadaan kering. Penilaian ke atas permukaan yang dimesin melibatkan kekasaran permukaan dan analisis mikrostruktur. Keputusan kajian menunjukkan bahawa tiada hubungan yang jelas di antara variasi kelajuan pemotongan dan suapan terhadap kekasaran permukaan. Umumnya, permukaan yang dihasilkan adalah sangat licin dengan nilai Ra berada dalam julat 0.10 μm – 0.43 μm dan analisis permukaan pada sampel–sampel ujikaji juga mendapati hampir tiada perubahan dapat dikesan pada mikrostruktur bahagian bawah permukaan yang dimesin. Walau bagaimanapun, pada kelajuan pemotongan tertinggi (160 m/min) dan suapan yang tinggi (0.02 mm/sisip), terdapat kesan termampat dan terherot pada mikrostruktur pada kedalaman yang sangat cetek iaitu lebih kurang 2.2 μm dari permukaan termesin. Kata kunci: Keutuhan permukaan, keluli perkakas terkeras, pengisaran hujung, mikrostruktur, perkakas karbida bersalut The effect of milling process on the surface integrity of newly machined surface of D2 tool steel is presented. The hardened AISI D2 (62 HRC) was machined under dry cutting conditions using a 20 mm diameter end–milling tool with indexable CVD coated carbide insert. Analyses revealed that the variation in cutting speeded and feed did not significantly affect the surface roughness of the machined surface. Generally, the surfaces produced are very smooth with Ra values in the range of 0.1 – 0.43 μm, and studies showed almost no microstructure alteration on the machined surfaces. However, at the highest cutting condition, i.e. a cutting speed of 160 m/min, and feed of 0.02 mm/tooth, some compression and distortion effects were detected on the microstructure at the very shallow depth of approximately 2.2 μm from the machined surface. Key words: Surface integrity, hardened tool steel, end-milling, microstructure, coated carbide tool

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

2009 ◽  
Vol 83-86 ◽  
pp. 56-66 ◽  
Author(s):  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin ◽  
A.N. Mustafizul Karim ◽  
A.M.K. Hafiz
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Inductive Heating ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Coated Carbide

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.

Enhancement of Machinability of Inconel 718 in End Milling through Online Induction Heating of Workpiece

2011 ◽  
Vol 415-417 ◽  
pp. 420-423 ◽  
Author(s):  
AKM Nurul Amin ◽  
Mohammad Ishtiyaq Hossain ◽  
Anayet Ullah Patwari
Keyword(s):  
Tool Life ◽  
Induction Heating ◽  
Inconel 718 ◽  
End Milling ◽  
Heating Temperature ◽  
Phase Transformation Temperature ◽  
Life Tool ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Conventional Machining

Abstract. This paper presents the outcome of a study on heat assisted end milling of Inconel 718 using inducting heating technique conducted to enhance the machinability of the material. The heating temperature maintained below the phase transformation temperature was aimed at softening the top removable material layers. The experimental results of both conventional and heat assisted machining were compared. The machinability of Inconel 718 under these conditions was evaluated in terms of tool life, tool wear morphology and chatter. The advantages of Induction heating is demonstrated by an longer tool life and lower chatter. The study showed that preheated machining facilitates up to 80% increase of tool life over conventional machining conducted using TiAlN coated carbide inserts.

Modeling & Optimization of Surface Roughness & Vibration Amplitude in Heat Assisted End Milling of SKD 11 Tool Steel Using Ball Nose Tool

2012 ◽  
Vol 538-541 ◽  
pp. 799-803 ◽  
Author(s):  
A.K.M. Nurul Amin ◽  
Muhd Hafiz B. Md. Saad ◽  
Muammer Din Arif
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Tool Steel ◽  
Vibration Amplitude ◽  
End Milling ◽  
Heating Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Primary Input ◽  
Coated Carbide

Tool steel - SKD 11 is frequently used in industries for making dies and molds. This grade is chosen for its toughness, strength, and hardness maintained up to high temperature. However, the same properties make the steel extremely difficult and expensive to machine using conventional approaches. Heat assisted machining has been found wide spread application in recent years to improve machinability of difficult-to-cut materials. This research paper presents the outcome of an investigation on heat assisted end milling of SKD 11 conducted on a vertical machining center using ball nose coated carbide inserts. The Design of Experiments (DoE) was done using the Response Surface Methodology, in order to develop empirical mathematical models of surface roughness and vibration in terms of cutting speed, feed, axial depth of cut, and heating temperature. The models were checked for significance using Analysis of Variance (ANOVA). 3-D response surface graphs of the interactions of primary cutting parameters with the responses were plotted. Optimization was then performed by using the desirability function approach. From the graphs and optimized results it was concluded that the primary input parameters could be controlled in order to reduce vibration amplitude and produce semi-finished machined surfaces applying induction heat assisted technique.

Multi-Criteria Optimization in End Milling of AISI D2 Hardened Steel Using Coated Carbide Inserts

2011 ◽  
Vol 264-265 ◽  
pp. 907-912
Author(s):  
A.N. Mustafizul Karim ◽  
Mohd Amri Lajis ◽  
A.K.M. Nurul Amin
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Aisi D2 ◽  
Machining Operations ◽  
Coated Carbide ◽  
Desirability Index

This paper proposes a multi-criteria optimization technique using the mathematical models developed by the response surface methodology (RSM) for the target responses combined with desirability indices for the determining the optimum cutting parameters in end milling of AISI D2 hardened steels. Different responses may require different targets either being maximized or minimized. Simultaneous achievement of the optimized (maximum or minimum) values of all the responses is very unlikely. In machining operations tool life and volume metal removed are targeted to be maximized whereas the machined surface roughness need to be at minimum level. Models showing the combined effect of the three control factors such as cutting speed, feed, and depth of cut are developed. However, a particular combination of parameter levels appears to be optimum for a particular response but not for all. Thus adoption of the method of consecutive searches with higher desirability values is found to be appropriate. In this study the desirability index reaches to a maximum value of 0.889 after five consecutive solution searching. At this stage, the optimum values of machining parameters - cutting speed, depth of cut and feed were determined as 44.27 m/min, 0.61 mm, 0.065 mm/tooth respectively. Under this set condition of machining operations a surface roughness of 0.348 μm and volume material removal of 7.45 cm3 were the best results compared to the rest four set conditions. However, the tool life would be required to compromise slightly from the optimum value.

Investigation on the Tool Wear Model and Equivalent Tool Life in End Milling Titanium Alloy Ti6Al4V

2018 ◽  
Author(s):  
Kai Guo ◽  
Bin Yang ◽  
Jie Sun ◽  
Vinothkumar Sivalingam
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Carbide Tool ◽  
Wear Model ◽  
Wear Process ◽  
Coated Carbide Tool ◽  
Coated Carbide

Titanium alloys are widely utilized in aerospace thanks to their excellent combination of high-specific strength, fracture, corrosion resistance characteristics, etc. However, titanium alloys are difficult-to-machine materials. Tool wear is thus of great importance to understand and quantitatively predict tool life. In this study, the wear of coated carbide tool in milling Ti-6Al-4V alloy was assessed by characterization of the worn tool cutting edge. Furthermore, a tool wear model for end milling cutter is established with considering the joint effect of cutting speed and feed rate for characterizing tool wear process and predicting tool wear. Based on the proposed tool wear model equivalent tool life is put forward to evaluate cutting tool life under different cutting conditions. The modelling process of tool wear is given and discussed according to the specific conditions. Experimental work and validation are performed for coated carbide tool milling Ti-6Al-4V alloy.

The Effects of Cutting Parameters on Work-Hardening of Milling Invar 36

2015 ◽  
Vol 1089 ◽  
pp. 373-376
Author(s):  
Xing Wei Zheng ◽  
Guo Fu Ying ◽  
Yan Chen ◽  
Yu Can Fu
Keyword(s):  
Work Hardening ◽  
Lattice Distortion ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Metallographic Structure ◽  
Metallographic Observation ◽  
Coated Carbide ◽  
Carbide Insert ◽  
Axial Depth

An experiment of face milling of Invar36 was conducted by using coated carbide insert, the microhardness was tested and the metallographic structure was observed to figure out the principles of work-hardening. The results showed that the depth of work-hardening ranges from 80μm to 160μm among the parameters selected in the experiments. The degree and the depth of work-hardening were significantly affected by the axial depth of cut and feed per tooth. The degree and the depth of work-hardening showed a tendency to increase with the increase of the axial depth of cut and feed per tooth. Compared with the axial depth of cut and feed per tooth, cutting speed had less influence on the degree and depth of work-hardening. The degree and depth of work- hardening decreased slowly with the increase of cutting speed. Metallographic observation showed that work-hardening layer consisted of the thermal force influenced layer and the force influenced layer, while the amorphous metallographic structure was observed in the thermal force influenced layer, and lattice distortion was observed in the force influenced layer.

Progressive Tool Failure in High Speed End Milling of Inconel 718 with Coated Carbide Inserts

2011 ◽  
Vol 188 ◽  
pp. 32-37 ◽  
Author(s):  
An Hai Li ◽  
Jun Zhao ◽  
Z.Q. Pei ◽  
S.G. Guo
Keyword(s):  
Abrasive Wear ◽  
Inconel 718 ◽  
Adhesive Wear ◽  
End Milling ◽  
Failure Mechanisms ◽  
Cutting Speed ◽  
Fatigue Wear ◽  
Edge Chipping ◽  
Tool Failure ◽  
Coated Carbide

The failure progression of coated carbide tools in end milling of Inconel 718 superalloy was investigated. Tool wear was measured and failure mechanisms were discussed in the experimental process periodically. The experimental results indicated that the tool failure mechanisms were synergistic interaction among abrasive wear, adhesive wear, and fatigue wear. However, abrasive wear and adhesive wear were the main failure mechanisms at the beginning, fatigue wear prevailed the upper hand around the time when edge chipping appeared, and after edge chipping abrasive wear and adhesive wear dominated until the failure time. In addition, the macroscopic failure of the cutting tools is closely correlated to the nucleation and propagation of the crack under cyclic mechanical and thermal impact forces. Mechanical fatigue wear was the key form of fatigue wear at lower cutting speed, while at higher cutting speed thermal fatigue wear was the dominant fatigue wear.

Cutting Forces and Surface Roughness in High-Speed End Milling of Ti6Al4V

2013 ◽  
Vol 589-590 ◽  
pp. 76-81
Author(s):  
Fu Zeng Wang ◽  
Jun Zhao ◽  
An Hai Li ◽  
Jia Bang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Forces ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Wide Range ◽  
Radial Depth ◽  
Coated Carbide

In this paper, high speed milling experiments on Ti6Al4V were conducted with coated carbide inserts under a wide range of cutting conditions. The effects of cutting speed, feed rate and radial depth of cut on the cutting forces, chip morphologies as well as surface roughness were investigated. The results indicated that the cutting speed 200m/min could be considered as a critical value at which both relatively low cutting forces and good surface quality can be obtained at the same time. When the cutting speed exceeds 200m/min, the cutting forces increase rapidly and the surface quality degrades. There exist obvious correlations between cutting forces and surface roughness.

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