Abstract
Hard machining is an efficient solution that can be used to replace the grinding operation in the mold and die manufacturing industry. In this study, an attempt is made to analyze the effect of process parameters on workpiece surface roughness (Ra) in the hard milling of JIS (Japanese Industrial Standard) SKD61 steel, based on a combination of the Taguchi method and response surface methodology (RSM). The cutting parameters are selected based on the structural dynamic analysis of the machine tool. A set of experiments is designed according to the Taguchi technique. The average Ra is measured by a Mitutoyo Surftest SJ-400, and then analysis of variance (ANOVA) is performed to determine the influences of cutting parameters on the given Ra. Quadratic mathematical modeling is introduced for prediction of the Ra during the hard milling process. The predicted values are in reasonable agreement with the observation of experiments. In an effort to obtain the minimizing Ra, a single objective optimization is employed based on the desirability function. The result shows that the percentage error between measured and predicted values of Ra is 3.2%, which is found to be insignificant. Eventually, the milled surface roughness under the optimized machining conditions is 0.122 µm. This finding shows that grinding may be replaced by finish hard milling in the mold and die manufacturing field.
Highlights
JIS SKD61 is a hot-work die steel that is widely used in the mold and die manufacturing industry.It is often utilized to manufacture hot extrusion dies, casting molds, and forging dies due to its significant toughness, high hardness, and sufficient resistance to high temperature fatigue properties.Generally, a mold and die manufacturing process consists of rough machining, heat treatment, and a finish grinding operation
These data were used to analyze the effect of cutting parameters on the surface roughness and to develop the mathematical models used to predict the surface roughness observed in the hard milling process
This study presented the optimization of the cutting conditions for Ra when hard milling JIS
Summary
JIS SKD61 is a hot-work die steel that is widely used in the mold and die manufacturing industry.It is often utilized to manufacture hot extrusion dies, casting molds, and forging dies due to its significant toughness, high hardness, and sufficient resistance to high temperature fatigue properties.Generally, a mold and die manufacturing process consists of rough machining, heat treatment, and a finish grinding operation. JIS SKD61 is a hot-work die steel that is widely used in the mold and die manufacturing industry. It is often utilized to manufacture hot extrusion dies, casting molds, and forging dies due to its significant toughness, high hardness, and sufficient resistance to high temperature fatigue properties. A mold and die manufacturing process consists of rough machining, heat treatment, and a finish grinding operation. This process is both costly and time-consuming. In order to enhance production and product quality in the mold and die manufacturing industry, the finishing grinding process is often replaced by a hard milling operation; this way, the product cycle time can be decreased, productivity increased, and the quality of finished products can be significantly improved [2]
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