Experimental investigations on micro-end-milling of hardened die steel: effects of high-speed and high-efficiency side cutting

Abstract

The need for micro-end-milling technology is increasing in recent years. However, it seems to be difficult to achieve high-precision and high-efficiency in micro-end-milling. The reason for this is that small-diameter endmills have small rigidity and are easily deformed during machining, and therefore the depth of cut has to be set small. Hence, the authors have analysed the processing phenomenon in detail. In the present paper, the cutting force, surface roughness, machining accuracy, and changes in tool wear were investigated in detail when hardened die steel was side-cut at high-speed. As a result, it was clarified that high-speed cutting can suppress the dimensional accuracy and shape error, and that high-efficiency machining can be achieved. It is not easy to perform theoretical analysis and numerical simulation in the machining analysis of micro end mills. In this study, experimental machining was first carried out, and sufficient useful knowledge was obtained.