Tribological effects of micromilling of hardened AISI D2 steel on tool wear and top burr formation

The study of micromilling of quenched and tempered AISI D2 steel is of utmost importance due to the accelerated wear of the micromilling cutting tool edge that intensifies the formation of top burrs, which is detrimental to the micromilled surfaces because it requires further surface finishing. In t...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2023-08, Vol.127 (11-12), p.5327-5341
Main Authors: dos Santos, Anderson Júnior, Reis, Bárbara Cristina Mendanha, Pereira, Natália Fernanda Santos, de Oliveira, Diogo Azevedo, Rubio, Juan Carlos Campos, Abrão, Alexandre Mendes, Câmara, Marcelo Araújo
Format: Article
Language:English
Subjects:
Advanced manufacturing technologies
Burrs
CAE) and Design
Chromium molybdenum vanadium steels
College campuses
Computer-Aided Engineering (CAD
Cutting tools
Cutting wear
Engineering
Industrial and Production Engineering
Machining
Measurement techniques
Mechanical Engineering
Media Management
Original Article
Plowing
Quenching and tempering
Rake angle
Scanning electron microscopy
Size effects
Surface finishing
Teeth
Titanium alloys
Tool steels
Tool wear
Tribology
Wear mechanisms
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Summary:The study of micromilling of quenched and tempered AISI D2 steel is of utmost importance due to the accelerated wear of the micromilling cutting tool edge that intensifies the formation of top burrs, which is detrimental to the micromilled surfaces because it requires further surface finishing. In this work, the effect of tooth feed per tooth and axial depth of cut on machining forces and top burr formation after dry micromilling of slots in quenched and tempered AISI D2 steel was evaluated. The results show that the passive force is approximately 32% higher than the radial and feed forces. Regarding burr formation, axial depth of cut was the most relevant parameter. Doubling axial depth of cut burr height increased by approximately 400%. Increasing feed per tooth reduces burr formation. The down cutting direction presented top burr heights approximately 23% higher when compared with up cutting. Attrition was the predominant tool wear mechanisms. Tool wear increases progressively with machining length raising the micromilling force components, which leads to rounding and increasing the radius of the cutting edge. Consequently, a negative rake angle is generated, inducing size effect and intensifying the material plowing mechanism.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-023-11819-x