Micro-milling of hardened AISI D2 tool steel

J.B. Saedon, S.L. Soo, D.K. Aspinwall, A. Barnacle

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

2 Citations (Scopus)
10 Downloads (Pure)


The paper presents an experimental investigation into the slotting of hardened AISI D2 (∼62HRC) tool steel using 0.5mm diameter coated (TiAlN) tungsten carbide (WC) end mills. SEM analysis of tool morphology and coating integrity was undertaken on all tools prior to testing. Tool wear details are given based on resulting cutter diameter and slot width reduction. In addition, cutting forces are also presented together with details of workpiece burr formation. A full factorial experimental design was used with variation of cutting speed, feed rate and depth of cut, with results evaluated using analysis of variance (ANOVA) techniques. Parameter levels were chosen based on microscale milling best practice and results from preliminary testing. Main effects plots and percentage contribution ratios (PCR) are included for the main factors. Cutting speed was shown to have the greatest effect on tool wear (33% PCR). When operating at 50m/min cutting speed with a feed rate of 8μm/rev and a depth of cut of 55μm, cutter diameter showed a reduction of up to 82μm for a 520mm cut length. SEM micrographs of tool wear highlighted chipping / fracture as the primary wear mode with adhered workpiece material causing further attritious wear when machining was continued up to 2.6m cut length. All tests produced burrs on the top edges of the slots which varied in size / width to a lesser or greater degree. Under the most severe operating conditions, burr width varied from approximately 50μm to more than 220μm over the 520mm cut length. Cutting forces in general were less than 12N up to test cessation.
Original languageEnglish
Title of host publicationMaterials and manufacturing technologies XIV
Subtitle of host publicationselected, peer reviewed papers from the 14th international conference on advances in materials and processing technologies (AMPT 2011)
PublisherTrans Tech Publications Inc
Number of pages6
ISBN (Print)9783037853467
Publication statusPublished - 1 Jan 2012
EventInternational conference on advances in materials and processing technologies (AMPT 2011), 14th - Istanbul, Turkey
Duration: 13 Jul 201116 Jul 2011


ConferenceInternational conference on advances in materials and processing technologies (AMPT 2011), 14th


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