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<p>Despite the widespread industrial use of structural steels, the quantitative relationship between tool wear progression and surface integrity in dry multi-fluted end milling remains insufficiently understood. This study provides a systematic investigation of flank wear evolution and surface roughness generation during dry down-milling of SS400 steel using a four-fluted AlTiN-coated carbide end mill. The novelty of this work lies in integrating statistical optimization with microstructural wear characterization to reveal the dominant wear mechanisms governing tool degradation in dry multi-fluted milling conditions. A Taguchi L9 orthogonal design was employed to evaluate the effects of cutting speed and feed rate on flank wear (Vb) and surface roughness (Ra), followed by signal-to-noise ratio analysis and ANOVA to determine the most influential parameters. The results demonstrate that cutting speed is the dominant factor affecting both wear progression and surface finish, while feed rate plays a secondary but consistent role. The optimal cutting parameters (150&#xa0;m/min cutting speed and 0.15&#xa0;mm/tooth feed rate) reduced flank wear and surface roughness by 27.73% and 29.15%, respectively, compared with the worst-performing condition, with statistical significance at the 95% confidence level. SEM and EDS analyses further reveal that abrasion, Fe-rich adhesion, coating delamination, and localized oxidation govern the wear progression under dry machining conditions. These findings provide new insights into wear mechanisms in multi-fluted dry milling and establish quantitative guidelines for parameter selection to improve tool life, surface integrity, and process reliability in industrial machining of structural steels.</p>

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Tool wear mechanisms and Taguchi-based optimization of flank wear and surface roughness in multi-fluted end milling of SS400 steel

  • 期刊论文

  • 发表日期：

    2026年4月10日

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  • Sakdipat Rakmae,
  • Worapong Sawangsri,
  • Thammarat Somthong,
  • Auangkul Moonrungsri

摘要

Despite the widespread industrial use of structural steels, the quantitative relationship between tool wear progression and surface integrity in dry multi-fluted end milling remains insufficiently understood. This study provides a systematic investigation of flank wear evolution and surface roughness generation during dry down-milling of SS400 steel using a four-fluted AlTiN-coated carbide end mill. The novelty of this work lies in integrating statistical optimization with microstructural wear characterization to reveal the dominant wear mechanisms governing tool degradation in dry multi-fluted milling conditions. A Taguchi L9 orthogonal design was employed to evaluate the effects of cutting speed and feed rate on flank wear (Vb) and surface roughness (Ra), followed by signal-to-noise ratio analysis and ANOVA to determine the most influential parameters. The results demonstrate that cutting speed is the dominant factor affecting both wear progression and surface finish, while feed rate plays a secondary but consistent role. The optimal cutting parameters (150 m/min cutting speed and 0.15 mm/tooth feed rate) reduced flank wear and surface roughness by 27.73% and 29.15%, respectively, compared with the worst-performing condition, with statistical significance at the 95% confidence level. SEM and EDS analyses further reveal that abrasion, Fe-rich adhesion, coating delamination, and localized oxidation govern the wear progression under dry machining conditions. These findings provide new insights into wear mechanisms in multi-fluted dry milling and establish quantitative guidelines for parameter selection to improve tool life, surface integrity, and process reliability in industrial machining of structural steels.