Tool Wear in Micro End Milling of Ultrafine Grain Steels
摘要
Micro-machining is one of the processes feasible for generating geometries or parts with precision and complexity regarding feature dimensions smaller than 1 mm. However, the achievement of enhanced machining performance and product quality requires a prior understanding on the tool-workpiece interface. This research determined the influence of cutting strategy and feed per tooth on tool wear and specific cutting force when cutting the ultrafine grain steel COS AR60 under end milling condition. Machining tests were performed in a CNC machining center Romi D600 provided with a high-speed spindle (60,000 rpm) without cutting fluid application. TiAlN coated carbide end mill (Ø 800 µm) was used in linear tool path with 60 m/min cutting speed, 160 µm depth of cut and feed per tooth of 3 and 10 µm/z. Analysis of Variance (ANOVA) with confidence interval of 95% was applied by considering one run and two replications. The results showed that tool wear levels and damages were influenced by tool feed per tooth and cutting strategy. Additionally, chipping damage during face milling with higher feed per tooth was predominant. Adhesion and abrasion wear mechanisms were significant for the same cutting pass under slot milling and down milling at a lower feed per tooth. Down milling and slot milling with 3 µm/z feed per tooth leaded to a better performance in terms of tool wear level on the major flank face. Specific cutting force decreased with feed per tooth and increased when milling channel.