Abstract
Plunge milling is a machining process used to remove material rapidly in roughing operations. It is known to offer significant increases in productivity as compared with conventional milling, especially in the case of deep milled workpieces. However, this improvement of productivity also entails the increase in machining conditions so it could be harmful to surface integrity. In this study the authors consider the case of a dry plunge milling process applied to two wrought Mg-Zr-Zn-RE alloys and one cast Mg-Zr-Zn-RE alloy with two different types of inserts. First, the study involves obtaining surfaces through experimental designs. Second, plunge milling conditions are correlated with surface integrity factors, such as roughness, microstructure and microhardness. This study suggests plunge milling conditions to offer a trade-off between surface integrity and chip flow.
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