Performance Evaluation of TiAlN Coated Tools on Pre-hardened Tool Steel in the Milling Process Using Vibrational Analysis

Milling is the fundamental process of the metalworking industry mainly for mould production. The correct choice of milling parameters, tool material and tool coating for machining pre-treated steels for plastic injection moulds improves tool performance and reduces costs. To analyze the tool performance in relation to the chosen parameters, it is necessary to analyze the vibration signals during the machining process, tool wear and the machined surface quality. Therefore, this work aims to evaluate the performance of three different coated tools with different designs: one tool coated with Cr-doped TiAlN (4 flutes) and the other two tools coated with TiAlN (5 flutes). The tools performances were evaluated during the milling of pre-hardened mould steel W 1.2711 in a dry environment using a cutting speed of 40 m/min and a feed tooth of 10 mm/tooth. Vibration analysis was considered in relation to tool wear. Surface roughness and tool wear in the milling process were considered parameters to measure the tool's performance. Tool wear was analyzed by optical microscopy. The results showed that tool 591 had the best performance in wear, but tool 233 promoted the lower surface roughness due to its special coating.