Investigation of workpiece surface roughness when micromilling hardened AISI D2 steel

Juri Saedon, Sein Soo, David Aspinwall, A. Barnacle

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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Abstract

The paper details an experimental evaluation of workpiece surface roughness following slotting of hardened AISI D2 (~62HRC) high carbon, high chromium cold work tool steel (employed extensively in the mould and die industry) using 0.5mm diameter coated (TiAlN) tungsten carbide end mills. A full factorial experimental design was carried out to investigate the influence of variations in cutting speed, feed rate and depth of cut, each at 2 levels. Results were assessed using analysis of variance (ANOVA) while main effects plots and percentage contribution ratios (PCR) for the primary variable factors were calculated. The ANOVA suggested that cutting speed had the greatest influence on surface roughness (38% PCR) followed by feed rate and depth of cut at 24% and 18% respectively, all 3 parameters being statistically significant at the 5% level. Surface roughness (measured in the feed direction) was found to be a minimum when operating at 50 m/min cutting speed with a feed rate of 1 μm/tooth and depth of cut of 15 μm, and varied between 0.11 to ~0.15 μm Ra over a 520 mm cut length.
Original languageEnglish
Title of host publicationProceedings of the 1st Joint International Symposium on System-Integrated Intelligence (Sys-Int 2012)
Subtitle of host publicationNew Challenges for Product and Production Engineering
EditorsBerend Denkena, Jurgen Gausemeier, Bernd Scholz-Reiter
PublisherPZH Verlag, Garbsen
Pages98-101
Number of pages4
ISBN (Print)978-3-943104-59-2
Publication statusPublished - 27 Jun 2012
Event1st Joint International Symposium on System-Integrated Intelligence 2012: New Challenges for Product and Production Engineering - IFW Leibniz Universitat Hannover, Hannover, Germany
Duration: 27 Jun 201229 Jun 2012

Conference

Conference1st Joint International Symposium on System-Integrated Intelligence 2012: New Challenges for Product and Production Engineering
Country/TerritoryGermany
CityHannover
Period27/06/1229/06/12

Keywords

  • Machinability
  • Micromachining
  • Steel
  • Surface integrity

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