Abstract
In this study, effect of surface roughness of end-mills on cutting performance of high-speed machining has been investigated. And a novel optimization design approach of the processing parameters for the high-speed cutting of the DIN 1.2344 tool steel has been also proposed. The characteristics indexes of cutting performance selected for this investigation are tool life and metal removal rate. The processing parameters include the surface roughness of the relief face of an end-mill, cutting speed, feed per tooth, axial cutting depth, and radial cutting depth. With multiple performance indices, the process is integrated. Consequently, the optimal combination of processing parameters is determined by performing grey relational analysis. Analysis results indicate that the effect of cutting speed and feed per tooth are significant for multiple performance characteristics. Additionally, the surface roughness of the relief face of an end-mill essentially affects the surface roughness of the processed workpiece. Due to slightly effect on cutting performance characteristics of the rough machining, the surface roughness of the relief face of 0.43±0.02 (μm) for grinding conditions can be used to improve tool grinding efficiency. Verification experiments revealed that the proposed optimization design approach of processing parameters is a highly potential means for improving a 9.1 (min) in tool life, a 1200 (mm3/min) in metal removal rate, a 230616 (mm3) in total metal removal volumes and a 0.044 (μm) in average surface roughness of workpiece under the high-speed cutting.
Highlights
Developments in machine tools tend towards high speed technology, including high-speed machining (HSM) and high-speed cutting (HSC), especially in high speed end milling applications [1] and [2]
The cutting performance of the end-mill for HSC is relevantly correlated with the processing parameters (the surface roughness of the relief face (A), cutting speed (B), feed per tooth (C), axial cutting depth (D), and radial cutting depth (E)), which are regarded as controllable factors in the study
From the above descriptions and analyses, the optimal processing parameters of DIN 1.2344 tool steel will be determined by grey relational analysis
Summary
Developments in machine tools tend towards high speed technology, including high-speed machining (HSM) and high-speed cutting (HSC), especially in high speed end milling applications [1] and [2]. The thermal effect of workpieces is insignificant since cutting chips remove most of the heat induced by processing, and cutting oil is seldom used. This trend contributes to environmental protection efforts. Major green cutting methods include tool materials, coating technology, tool geometry design, chip control, coefficient of tool-face friction with the workpiece, and selection of cutting. Green cuttingrelated developments and applications depend on technological advances in machinery and cutting tools
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