Abstract
It is estimated that around 65% of the cost of a die or mould is related to the machining processes. Moreover, the literature says that 70% of the time spent in the machining processes of this kind of parts is used in finishing and semi-finishing operations. The high complexity of the machined surfaces makes mandatory the use of ball nose tools, with large overhang, what increases vibration in the process. These problems have to be minimized, since dies and moulds demand a very good surface finish and tight dimensional tolerances. A frequently used strategy to attenuate these problems is to carry out semi-finishing operations with cutters containing circular inserts, because these inserts produce smooth transitions among the passes and a smaller and more uniform stock material for the finishing operation. The main goal of this work is to evaluate the performance of rounded inserts of carbide and cermet in the semi-finishing milling (called toroidal milling) of H13 steel with hardness of 50 HRc. The influence of radial depth of cut, cutting speed and feed per tooth on tool life will also be considered. It also intends to test the feasibility of using minimum quantity of lubricant (MQL) technique instead of dry cutting in this kind of machining operation.
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