Terms Of Tool Life Research Articles

Cutting Performance and Wear Behavior of Self‐Developed Silicon Nitride Ceramic End Mills with Optimized Structure for High‐Speed Machining of GH4099

Ceramic tool materials possess a wide range of potential in machining nickel‐based superalloys due to their superior wear resistance, high‐temperature hardness, and strong chemical stability. Herein, a structural optimization scheme of self‐developed silicon nitride ceramic end mill based on stiffness enhancement and performance improvement is proposed, and the key geometric angular parameters scope of the self‐developed ceramic end mills are prioritized via the finite‐element simulation method. Through precision grinding manufacturing and sandblasting pretreatment, the cutting performance and tool wear behavior of three optimized self‐developed silicon nitride ceramic end mills (called S4‐1, S4‐2, S4‐3 respectively) are comprehensively analyzed in comparison, including cutting force, milling temperature, surface quality, and tool life. The results indicate that the cutting force and cutting temperature of all the optimized ceramic end mills are effectively restrained compared with the nonoptimized ceramic tool(S4), and the final workpiece surface roughness is significantly reduced. Further, better surface quality can be obtained by optimized ceramic mills. In terms of tool life, ceramic end mill with optimized construction in best can be increased by up to 1.9 times. The wear mechanism and pattern of the three optimized ceramic milling tools are similar, which is adhesive wear, diffusion wear, and notch wear. Overall, the effectiveness of the optimization scheme for ceramic end mill is successfully verified.

Machining of Hard-to-cut AISI 4462 Duplex Stainless Steel with an Environmentally Friendly Approach with Vortex Tube

Machining is a manufacturing process that can be used to produce precision machine parts and has many advantages. The first is the ability to achieve superior surface quality. Tool wear is an inevitable phenomenon that occurs during machining. It is affected by many machining conditions; therefore, this process needs to be monitored and controlled. In this study, tool wear and surface roughness tests were carried out on AISI 4462 duplex stainless-steel materials, known to be a hard-to-cut material. For this purpose, tool wear and surface roughness analyses were implemented by using the environmentally friendly vortex tube cooling system in addition to wet turning conditions for the first time. For both methods, experiments were conducted at a 1 mm depth of cut, 120 m/min cutting speed, and 0.1 mm/rev feed with a 90 mm cutting length for each pass. Both tool wear and surface roughness were examined at the end of each pass. The analysis showed that wet turning gave better results in terms of tool life (19.8 minutes of tool life) compared to 11.1 minutes of tool life in vortex turning. In contrast, the surface roughness values differed up to two times in some experiments, and the vortex tube experiments gave better surface roughness values in all passes. In addition, the vortex tube experiments showed less built-up-edge (BUE) formation than the wet-turning experiments.

Evaluation of tool wears mechanism considering machining parameters and performance parameters for titanium alloy in turning operation on CNC

ABSTRACT Titanium alloys are frequently utilised in applications that call for high strength at high temperatures as well as excellent mechanical resistance. This alloy has excellent mechanical properties that enable improved performance from titanium alloys. In the current research, Taguchi L25 orthogonal array of experiments were conducted first, and MCDM techniques and ANNOVA were utilised to forecast the influencing machining factors. From MCDM three methods (SAW, VIKOR & TOPSIS) prediction algorithms which rank one for experiment no. 2. Experiment results shows that experiment no. 02 gives optimum/best results in terms of Tool life and surface roughness. While the process parameter has values cutting speed = 80 rpm, Feed rate = 018 rev/mm, Depth of cut = 0.12 mm, and Rake angle = 14 degrees. From ANOVA outcome for surface finish it is noticed that the process parameter rake angle is having Rank 01 for all levels. Thus rake angle is major influencing parameter to achieve a better quality of surface roughness. While in case of flank wear it is crystal clear that the process parameter DOC is having Rank 01 for all levels. Thus DOC is most influencing parameter to achieve lesser flank wear and better quality of tool life.

Comparative life cycle analysis of environmental and machining performance under sustainable lubrication techniques

One of the issues confronting manufacturers is the requirement for establishing sustainable production methods, which poise between economic feasibility and ecological preservation. Alternative sustainable cutting fluid methods must be developed since the traditional lubricants employed in machining operations are unsustainable from the environmental impact point of view. The balance between energy-production demand and quality-productivity is required for sustainable production. In this respect, this research studies the tool life, machining efficiency, energy consumption, and carbon emission under dry, flood machining, and minimum quantity lubrication machining. This study comprises two parts: evaluation of machining characteristics in terms of tool life, machining efficiency, energy consumption, and carbon emission, and the life cycle assessment (LCA) of inventories used during machining experimentation. The outcomes of this novel work revealed an increase of 42% and 61% in tool life at a cutting speed of 185 ​m/min under flood and MQL media than dry machining. At a cutting speed of 185 ​m/min in three different lubricating conditions, the percentage increase in the efficiency was 31%, and 28% for dry, flood, and MQL machining. In MQL machining, due to more uniform lubrication than flood machining, energy usage decreases by 38%, 32%, and 27% at the rate of metal removal of 93.67, 131.68, and 152.36 ​mm3/min. Also, A decrease in CO2 emissions of 16%, 21%, and 18% was attained in MQL machining than flood machining at 185, 215, and 245m/min cutting speeds. Furthermore, this also compares life cycle inventory analysis in dry, flood, and minimum quantity lubrication. Gate-to-gate approach methodology adopted for LCA analysis of system boundaries and functional unit to examine the environmental impression through ReCipe 2016, Endpoint (H) methodology. Sustainable assessment through life cycle analysis determined that dry and mist machining are more sustainable than wet machining.

Roles of Eco-Friendly Non-Edible Vegetable Oils in Drilling Inconel 718 through Minimum Quantity Lubrication

Metal cutting fluids (MCFs) have played a principal role as coolants and lubricants in the machining industry. However, the wide use of mineral-based oil MCFs has contributed to an adverse effect on humans and the environment. Thus, to overcome the adverse effects of mineral-based oil MCFs, eco-friendly vegetable oil, which is non-edible oil, has been implemented to overcome the issues related to edible oil such as manufacturing costs and food shortages. This study investigated the performance of three different types of non-edible oil, namely castor, neem, and rice bran oils in drilling Inconel 718 using a coated titanium aluminum nitride (TiAlN) carbide drill towards tool life, tool wear, surface integrity, dimensional accuracy, and chip thickness. The MCFs were implemented under the minimum quantity lubrication (MQL) condition at a 50 mL/h flow rate using different cutting speeds (10, 20 m/min) and a constant feed (0.015 mm/rev). The results showed that castor oil minimizes the rapid growth of tool wear and prolongs the tool life by 50% at 10 m/min as compared to rice bran oil. At 20 m/min, castor oil obtained the lowest values of average surface roughness (1.455 µm) and chip thickness (0.220 mm). It was also found that different cutting speeds did not contribute to any significant trend towards hole diameter and roundness for all MCFs. The outstanding performance of castor oil proved that the oil is a potential alternative as an eco-friendly MCF for a cleaner machining environment. Castor oil was determined to be optimum in terms of tool life, tool wear, surface roughness, and chip thickness.

Modelling of Metal Removal Rate in Copper Alloy Milling Using MATLAB

The copper found in Earth’s soil ranks fourth in abundance among structural metals. Copper alloys are composed of copper and other elements. Most commonly, these alloys are used in aerospace, medical, and energy applications, but they are also used in many other areas. The amount of the stabilizing agents and the temperature determine which phase copper alloys exist in, including α, α + β, and β. The temperature in the cutting zone is one of the most important factors to control when machining copper alloys. Copper alloys have low thermal conductivity and high heat capacity, meaning that they have low heat conduction from the cutting zone, which leads to the built-up heat in the cutting edge. As the workpiece and cutting tool moves at different speeds, the temperature is strongly affected by the cutting speed. The physical and chemical properties of tool wear progression have been used in several studies and research projects to model tool life and metal removal as a result of this fact. The focus of this article is on establishing a model connecting cutting parameters and measured responses in terms of tool life, using the design of experiments and metamodeling to establish a model that can be used to predict tool life from milling experiments. In order to secure reliable machining operations, these models were designed for customer recommendation and cutting data optimization. The study focused on copper alloys 6Al-4V, the most common being α + β alloy. In conclusion, the two models developed in this study are able to predict the tool life based on the cutting speed and radial width of cuts. As long as certain parameters are met, the models will ensure the highest possible metal removal rate.

Performance analysis of Ti2AlN superimposed WC cutting tool

This article presents the development of superimposed Ti2AlN MAX phase coatings on cutting tools through reactive co-sputtering technique in dry machining of Ti-6Al-4 V. The effect of varying nitrogen flow rate during the reactive co-sputtering process and its influence on cutting properties has also been discussed. The predictive modeling along with validation of experimental results were carried out using response surface methodology (RSM) and optimized condition for cutting force were obtained using composite desirability function. Machining studies using the superimposed Ti2AlN coatings reduced the cutting force by 23–35 % when compared to commercial coatings. Investigation of cutting mechanics revealed an increase of shear angle by 3–5 % and decrease in friction angle by 20 %. The superimposed MAX phase coatings also reduced the friction coefficient by 34 % during dry turning of Ti-6Al-4 V. The superimposed Ti2AlN coatings were held responsible to improve the performance of the tool by 21–30 % in terms of tool life when compared to commercial tool. It could be inferred that the superimposed Ti2AlN coatings reduced the effect of chemical affinity between the tool and workpiece, eliminating the formation of built-up edge at rake face of the tool.

Comparative performance evaluation between HSN-TiAlxN and TiCN coated carbide tools in hard turning of AISI D6 steel

Hardened steels are exclusively in great demand particularly in mould and die making industries. Cutting tools such as ceramic, CBN, PCBN and PCD are normally preferred to machine hard to cut materials but are expensive in terms of cost. The usage of carbide tools with proper coatings within a particular machining range, a comparable tool life can be achieved with lesser cost in hard machining. The present experimental work dealt with a comparative assessment among newly developed TiAlxN and traditional TiCN coated carbide tools in terms of tool life, tool (crater and flank) wear, cutting temperature and surface integrity in dry hard turning of AISI D6 steel. The experiments with 16 trials are performed according to L16 orthogonal array by considering various machining parameters such as cutting speed, depth of cut and feed. Finally, the measured tool life was considered in the Gilbert’s economic approach, to perform a distinctive cost analysis which justified the cost-effectiveness of coated carbide tool in hard turning. Among the tools used, TiAlxN coated carbide tool for hard turning application promises and excellent machinability performances in terms of (i) lower flank and crater wears (ii) longer tool life, (iii) improved surface integrity, (iv) minimum cutting temperature and (v) considerable economic advantages as the production cost is reduced by 6%. The nanostructured TiAlxN coating accomplished by physical vapour deposition (PVD) technique considerably developed lower range of tool wear (VB = 0.053–0.134 mm), produced surface finish (Ra) within 0.35–1.07 µm, and following the surface quality at par closer to cylindrical grinding because of superior surface hardness, wear resistance, and bonding strength of coating material. TiAlxN coated carbide tool offered significant cost savings (Rs. 82.21 in Indian currency) in production costs in comparison to hard turning via. TiCN (Rs. 87.10) coated insert.

Carbon emissions, techno-economic and machinability assessments to achieve sustainability in drilling Ti6Al4V ELI for medical industry applications

In the last decade, cryogenic machining has made a significant impact as a sustainable machining technique, demonstrating machinability improvements in terms of tool life, surface quality of machine parts, low environmental effects and reduced cost of overall machining operation. A near-to-dry machining technique, Electrostatic Minimum Quantity Lubrication (EMQL) has also emerged as a sustainable machining technique, which is an environmentally-friendly alternative to the flood machining process. Although these coolant/lubrication strategies have been studied extensively, there is no direct comparison of both these machining techniques in the aspects of ecology, economy and machining performances. In this novel study, cryogenic liquid carbon dioxide (LCO2) and EMQL techniques are used for high-speed drilling of Ti6Al4V ELI (extra low interstitial) grade, and the sustainability and machinability assessment of these techniques are evaluated which can help medical implant manufacturing industries to implement these techniques as an economic and sustainable replacement of the conventional cooling/lubrication techniques. Ti6Al4V ELI is widely used in the medical industry for Hip and Knee joint endoprosthesis, bone screws, collar bone and dental implants. The sustainability aspects were evaluated in terms of carbon emission and cost analysis of the processes. It was found that the EMQL cutting condition exhibited 27.69% higher carbon emission and 67.60% higher cost of machining operation compared to cryogenic LCO2 cutting condition. Moreover, the tool life experienced when machining using cryogenic LCO2 cutting condition was at least 4 times higher than tool life found when using the EMQL cutting condition. The surface roughness of the workpiece material was higher (56.40%) when using the EMQL coolant. These results were attributed to adhesion wear and chip clogging phenomena which were found to be the main factors for reduced tool life and higher surface roughness in EMQL cutting condition. Therefore, from this study, it can be concluded that cryogenic LCO2 coolant performs significantly better compared to EMQL coolant, providing improved machinability of the titanium workpiece and superior sustainability of the cutting operation.

Analysis of surface roughness and energy consumption in turning of C17500 copper alloy under different machining environments and modellings with response surface method

The difficulties in machinability due to the developments in the technical properties of engineering materials increase the importance of machinability indicators such as surface quality, power or energy consumption and tool life in terms of sustainable machining. In this context, the machinability of a copper-beryllium alloy (C17500), which is used in a wide range of industries and also characterized as a hybrid material, was investigated in vortex tube cooling and dry cutting environments. First, turning experiments were performed with a coated carbide tool and varying cutting speed, feed rate and depth of cut. In the experiments, the total energy consumed during turning and the roughness of the machined surfaces were measured, and analysed experimentally and statistically. In the second stage, mathematical models were developed for the total energy consumption and average surface roughness for both cutting environments with the response surface method. As a result, the chip formation process in the turning of the Cu alloy under vortex tube cooling negatively affected the cutting power and positively contributed to the surface quality. Due to the fact that vortex tube cooling creates a cooling effect rather than lubrication, built-up layer/built-up edge (BUL/BUE) formation on the tool cutting edges caused the change in the tool geometry and thus the chip removal process became more difficult and increased the energy consumption. On the other hand, in the vortex tube cooling application, the surface roughness decreased by an average of 31.4% compared to dry cutting. Furthermore, the predictive mathematical models developed for the total energy consumption and the mean surface roughness can be used with high reliability.

Experimental Study of Quarry Dust and Aluminium Oxide Suspension as Cutting Fluid for Drilling of Titanium Alloy

In the aerospace field, titanium alloys are extensively used for the airframe and engine parts to improve aircraft fuel consumption. Drilling through these parts in a single-shot process to produce high quality holes is challenging. During drilling, high temperatures are generated owing to the friction between the cutting tool and workpiece, causing the process becomes inefficient in terms of tool life and surface quality. To reduce the temperature produced in the cutting zone, different types of cooling techniques during drilling have been used by researchers. In this study, the feasibility of quarry dust suspension as coolant in drilling of titanium alloy was performed. The effects of different concentrations of quarry dust on surface roughness, thrust force, and burr formation were evaluated, and their machining performances were compared with those obtained using aluminium oxide suspension. Before the experiments, both suspensions were prepared by dispersing quarry dust and aluminium oxide particles into deionised water at various concentrations ranging from 0 wt% to 0.10 wt%. Results indicated that by using 0.06 wt% of quarry dust suspension, thrust force and surface roughness showed an improvement by 8.31% and 18.29%, respectively, compared with those of aluminium oxide suspension at the same concentration. The burr height formed at the drilled holes using 0.06 wt% of quarry dust was also lower than that formed with aluminium oxide suspension at the same concentration.

An overview of the machinability of alloy steel

Machinability is an important aspect for the machining of any materials. In general, it is controlled by means of tool life, surface roughness, power consumption, chip morphology, cutting forces, cutting fluid and material removal rate. Furthermore, it is also affected the microstructure, grain size, hardness, yield, tensile strength and chemical composition of the work piece material and tool materials. Advanced materials such as alloy steel, structural ceramics, and hardened steel are difficult to machine using conventional tool materials. The machining parameters such as depth of cut, cutting velocity and feed rate play a very important role to achieve high quality of surface finish on the machined surface. High interface temperatures at the tool tip and work piece material resulted poor surface finish and increases cutting forces and tool wear. A high cutting speeds with high feed and depth of cut causes high heat generation which reduces the tool substrates bonding strength resulting in accelerated tool wear and reducing tool life. In this article influence of heat treatment to enhance machinability alloy steel reviewed in terms of tool life, surface roughness, cutting forces and chip morphology. This article will be very useful for the students, research scholar and industrialist working in the area of machining.

Effects of laser-textured on rake face in turning PCD tools for Ti6Al4V

The demand inherent to the aeronautical industry in terms of productivity and quality requirements leads to develop new cutting tools. Hence, PCD tools meet the requirements in productivity while machining low machinability aeronautical alloys such as Ti6Al4V. Tool chipbreakers play a considerable role in terms of tool life. However, due to the extreme conditions (temperature and pressure) required to manufacture PCD tools, any complex geometry on tool rake faces is not viable, so chipbreakers are not possible, except for those external to inserts. This work proposes a groove-type laser engraved chipbreaker design and a manufacturing methodology, with experimental validation on turning a Ti6Al4V workpiece. The so-manufactured chipbreakers achieve titanium alloy chip fragmentation, making easy chip removal from the cutting zone. A set of experiments involving various laser parameters to characterize the PCD depth and surface integrity and experimental validation for those chipbreakers designs were carried out in finishing cutting conditions. The optimum parameters for the engraving of PCD were found, obtaining satisfactory breakage of titanium chips. Chip length was always below 17.29 mm.

Experimental investigation and fuzzy TOPSIS optimisation of Ti6Al4V finish milling

ABSTRACT Ti6A14V is a well-known ‘Difficult to Cut’ material in the aerospace industry. Ti6Al4V shows strain hardening, poor thermal conductivity and chemical reactivity at elevated temperatures, which implies low machinability. This work presents an experimental investigation of 3D finish milling of Ti6Al4V material by Taguchi design of experiments, having L25 array. The considered process parameters are cutting speed, feed, depth of cut, tool type, coolant type and computer aided manufacturing strategy. The experimentation is conducted on the 3D finish milling process, and the performance in terms of tool life, tool wear and surface integrity were recorded. The fuzzy technique for order of preference by similarity to ideal solution, a multiple-criteria decision-making tool, was applied on experimental responses. The yielded optimum results are derived at minimum cutting speed, moderate depth of cut, feed rate per tooth and collaboration under high concentrated wet lubrication using a PVD-TiAlN cutting tool driven by streamline computer aided manufacturing strategy. In addition, analysis of variance confirms the influential process parameter contribution on the respective performance. Finally, optimised process parameters were applied for the gear bracket finish milling through streamline CAM strategy, which results in minimum flank and crater wear with an average surface roughness of 0.17 microns.

Graph Theory and Matrix Approach for Machinability Enhancement of Cryogenic Treated Cobalt Bonded Tungsten Carbide Inserts

Cryogenic treatment is a sustainable manufacturing process preferred to improve the properties of the material. In the present study, the effect of cryo treated tungsten carbide cobalt bonded insert (WC-Co) measured in terms of tool life and surface finish on dry turning on high strength AISI4340 steel at different machine parametric conditions. The observations of Untreated (UT) and Deep Cryo Treated (DCT) inserts were compared. Formation and the distribution of eta phase carbides are verified by Scanning Electron Micrograph (SEM). The DCT insert shows a reduction in 27.27% tool wear with an acceptable level of surface finish. Taguchi's coupled Graph Theory and Matrix Approach (TC-GTMA) is used to predict the optimum machining condition and to substantiate the results the validation experiment is conducted and found satisfactory.

Wear mechanisms of PcBN tools when machining AISI 316L

This paper investigates the machinability of AISI 316L stainless steel without and with NMI treatment, when machined with three different PcBN tool grades: low cBN content (50% vol.), medium (65% vol.) and high (90% vol.). The NMI treatment consisted of resulfurized and Ca-treated steels with two different Si/Al ratio. The tool materials were evaluated in terms of tool life, showing the best performance for the medium cBN content grade. Results showed that the crater wear has a more significant effect on the tool performance than the standard wear criteria of maximum flank wear. The worn tools were examined using scanning electron microscopy (SEM), focused ion beam (FIB) and transmission electron microscopy (TEM). In most cases, the crater exhibited three distinct regions from the edge to the end of the contact zone: the plateau, middle crater, and the upper region. Plateau and crater region displayed tool protective layer (TPL), consisting mostly of Al, Si, Mg and Ca-oxides; and some dimples in the tool from preferential wear of cBN grains. In the upper region of the best performing material, a ~1.5 μm thick TPL of mostly MnCr2O4 spinel was found, a result of the transfer of Mn- and Cr-rich oxide NMIs found in this material or oxidation of workpiece material, during the machining process.

The effects of cooling applications on tool life, surface quality, cutting forces, and cutting zone temperature in turning of Ni-based Inconel 625

Due to their high-temperature resistance, nickel-based super alloys are used in many fields, especially in the aviation and aerospace industries. In addition to these advantages, there are some machining difficulties. Some cooling methods are used to minimize the machining difficulties of these materials. For this purpose, in this study, tool life, tool wear, surface roughness (Ra), cutting forces (Fc), and cutting zone temperature (T) were investigated in turning Inconel 625 super alloys under different cooling conditions. Experiments were carried out under three different cutting conditions (dry, minimum quantity lubrication [MQL], and vortex cooling methods). Three feed rates (0.08, 0.1, and 0.12 mm/rev) and three cutting speeds (60, 80, and 100 m/min) were used. Tool wear tests were conducted at average cutting speed and feed rate (80 m/min and 0.1 mm/rev). After the experiments, it was found out that the cooling application positively affects in terms of tool life, cutting zone temperature, and surface roughness. The lowest wear occurred as 0.136 mm in experiments with MQL. The best values for cutting forces, surface roughness, and cutting zone temperatures were also obtained with MQL.

A comparative study on tool life and wear of uncoated and coated cutting tools in turning of tungsten heavy alloys

In turning of tungsten heavy alloys (WHAs), severe tool wear and short tool life are usually encountered. In this paper, we investigated the cutting performance of common cutting tool materials in turning of WHAs under oil lubrication condition. Experiments were conducted on three different cutting tools, namely, the TiAlN-coated carbide cutting tool, uncoated carbide cutting tool, and Ti (C, N)-coated cermet cutting tool, to study their tool lives and wear behaviors. Tool life, wear progression, and cutting force were investigated under different cutting parameters. Meanwhile, the wear patterns and mechanisms were studied. Flank wear was found to be the major wear pattern of the three selected cutting tools. In all the selected cutting tools, adhesion and oxidation were the main wear mechanisms discovered. Compared with the other cutting tools, chipping, notch wear, and diffusion wear were observed in the uncoated carbide cutting tool. The experimental results revealed that the TiAlN-coated carbide cutting tool exhibited a better cutting performance than the uncoated carbide cutting tool and Ti (C, N)-coated cermet cutting tool in terms of tool life which reaches 15 km by using optimized parameters.

Analysis of Solid Carbide Drilling Performance on AISI 316L Austenite Stainless Steel using MQL (Minimum Quantity Lubrication) using Peck Drilling Approach

Minimum Quantity Lubrication (MQL) minimizes refrigerants and lubricants mixed with air to foster environmental sustainability. Austenitic AISI 316L stainless steel is often used for the aviation, biomedical equipment and food appliances. However, low machinability of this material makes it difficult to cut resulting low hole surface quality. The objective of the study is to evaluate the drill performance of solid carbide tools while drilling AISI 316L austenite stainless steel and to study the effect of drilling parameters, cutting speed (Vc), feed rate (Fr) and drill geometry (point angle) on tool life, surface integrity and holes accuracy. Solid carbide drilling performance analysis on AISI 316L Austenite Stainless Steel using MQL was assessed in terms of tool life, surface roughness, and hole accuracy. Investigation for optimal conditions of cutting speed, feed rate and point of angle when drilling AISI 316L austenite stainless steel would obtain the optimum output indicates longer tool life, better surface roughness and adequate accuracy in high-speed machining conditions. This MQL oil-air flow is accurately measured and sent to the drill tool edge. The cutting speeds applied for the machining process are 100m / min, 130m / min and 150m / min. For feed rate parameters, the selected values are 0.05mm / rev, 0.1mm / rev and 0.15mm / rev. Rotational drill angles are 110 °, 120 ° and 130 °. The peck drilling investigation is performed on high-speed milling machines keenly will provide guidance to produce good and optimal machining settings of cutting speed, feed rate and angle point to others when they want to drill a hole.

Performance of Multilayer Coated and Cryo-treated Uncoated Tools in Machining of AISI H13 Tool Steel—Part 2: HSS End Mills

This part of the study aimed to investigate the effects of cryogenic treatment applied to uncoated high speed steel (HSS) end mills on cutting forces (Fc), surface roughness (Ra), and tool life. The milling tests were performed at four cutting speeds (40, 50, 60, and 70 m/min), three feeds (0.018, 0.024, and 0.03 mm/rev), and a depth of cut (2 mm) under dry and wet conditions. Three categories of uncoated HSS end mills were used in the tests: conventional heat treated (CHT), cryo-treated (CT), cryo-treated and tempered uncoated (CTT), and TiAlN/TiN multilayer coated (MLC) end mills. The test results showed that the lowest values of Fc and Ra were measured with the use of MLC end mills. However, the cryogenic treatment provided in a reduction in Fc and Ra values. In addition, under wet conditions, the CTT end mills exhibited better performance than the CHT ones by 71.4%. The test results showed while cryogenic treatment is a useful and cheap application in steels, it does not have the ability to compete with coating technology in terms of tool life in milling of hot work tool steel. This paper is organized into two sections. In the first section, cutting performance of cryo-treated and multilayer coated end mills is evaluated. In the second section, performance comparison of cryo-treated WC-Co (Part 1), HSS (Part 2), and MLC end mills in milling of AISI H13 hot work tool steel is presented.