Evaluating surface roughness, tool life, and machining force when milling free-form shapes on hardened AISI D6 steel
Evaluating surface roughness, tool life, and machining force when milling free-form shapes on hardened AISI D6 steel
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DOI：
10.1007/s00170-015-7525-0
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发表时间：
2016-02
期刊：
影响因子：
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通讯作者：
Innocenzo Scandiffio;A. E. Diniz;Adriano Fagali de Souza
中科院分区：
文献类型：
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作者：
Innocenzo Scandiffio;A. E. Diniz;Adriano Fagali de Souza
今天，AISI D6工具钢已被用于制造需要高机械性能的模具和模具。这么硬的材料要加工可不是件容易的事。铣削自由几何形状的D6是一个挑战，通常面临的模具行业。因此，本文提出了使用球端硬质合金刀具自由铣削硬质材料AISI D6工具钢的研究。考察了刀具路径方向（上下方向）和刀具与工件表面接触对加工力、表面粗糙度、刀具磨损和刀具寿命的影响。实验在两种工件上进行：第一种工件的铣削面为圆柱形，第二种工件的铣削面为斜面（有三种不同的倾角）。结果表明，对刀具寿命影响最大的因素是刀具振动。振动越高，刀具寿命越短。此外，与铣削普通材料的模具和模具不同，切削过程中刀尖中心的啮合对硬材料的加工过程是有利的，因为它提高了切削稳定性，从而降低了表面粗糙度并增加了刀具寿命。
Today, the AISI D6 tool steel has been employed in the manufacture of dies and molds that require high mechanical properties. Such hard material is not trivial to machining. Milling free-form geometries of D6 is a challenge usually faced at die and mold industries. Therefore, the current paper presents an investigation of free-form milling of hard material AISI D6 tool steel using a ball-end cemented carbide cutting tool. The influence of the toolpath direction (descendant and ascendant) and tool-workpiece surface contact were examined, and the machining forces, surface roughness, tool wear, and tool life were evaluated. The experiments were performed in two kinds of workpieces: in the first one, the milled surface was a cylindrical and in the second, the surface was inclined planes (with three different inclinations). The results indicate that the most influential factor for tool life was tool vibration. The higher the vibration, the shorter the tool life. Further, unlike milling of ordinary materials for molds and dies, the engagement of the center of the tool tip during cutting is advantageous for the machining process of hard materials because it improves cutting stability, thus reducing surface roughness and increasing tool life.