An Investigation of Power Consumption in Milling AISI P20 Plastic Mold Steel By Finite Elements Method

Abstract

Mold steels lead the production of products used in all areas of our lives. Performing the machinability tests of these materials with the finite element method (FEM) provides cost and time savings. In addition, it provides to get away from physical experiments that provide high power consumption. Because consumption must be eliminated in order to ensure a sustainable and clean production. In this study, AISI P20 mold steel was milled using the finite element method. Same directional milling and corner milling operations were performed. The effects of the cutting parameters used in the milling process on the power consumption were investigated. Four different feed rates (0.075-0.113-0.169 and 0.253 mm/tooth) four different cutting speeds (170-200-230-260 m/min), and two different cutting depths (0.075-1.5 mm) were used in the study. Power consumption values were obtained by taking the resultant values of the cutting forces (Fx, Fy and Fz) occurring during cutting. According to the results obtained, it was concluded that the power consumption increased with the increase in feed rate, cutting speed and cutting depth. The highest power consumption value was determined as 8041.91 W, and the lowest power consumption value was determined as 1748.10 W. As a result, it has been shown that the FEM and statistical evaluation yield consistent results.