Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel

With the advent of several advanced difficult-to-cut materials, and with the availability of heat resistant tool materials has posed a great challenge in industries. Hardened steel is one of these difficult-to-cut materials. During the last few decades numerous studies have been conducted to impr...

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Main Authors:	Amin, A. K. M. Nurul, Lajis, M. A., Karim, A.N. Mustafizul
Format:	Book Chapter
Language:	English
Published:	IIUM Press 2011
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://irep.iium.edu.my/23584/ http://irep.iium.edu.my/23584/ http://irep.iium.edu.my/23584/4/chp5.pdf

id	iium-23584
recordtype	eprints
spelling	iium-235842012-09-05T02:16:49Z http://irep.iium.edu.my/23584/ Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel Amin, A. K. M. Nurul Lajis, M. A. Karim, A.N. Mustafizul TJ Mechanical engineering and machinery With the advent of several advanced difficult-to-cut materials, and with the availability of heat resistant tool materials has posed a great challenge in industries. Hardened steel is one of these difficult-to-cut materials. During the last few decades numerous studies have been conducted to improve the machinability of these materials and many large organizations have invested considerably in exploring and developing new techniques to minimize machining costs of these materials while maintaining their quality requirements. The benefits for the manufacture of components from hardened steel are substantial in terms of reduced machining costs and lead times, in comparison to the more traditional route which involves machining in the annealed state, heat treatment, grinding or electrical discharge machining (EDM), and manual finishing [1]. Recent advances in cutting tool and machine tool technologies have opened up new opportunities for investigation in machining hard materials and especially for bulk removal of material. For these reasons the growing interest for hot machining process is being developed in industry. In this method work-piece is softened by heating and thereby shear strength is reduced [2]. The technology of hot machining is not new. Previous generations of this technology employed low-grade heat sources such as flame, electrical resistance, induction and plasma arcs [3]. Ozler et al. [4] integrated plasma gas heating in turning of austenitic manganese steel and he noticed that tool life increases when heating temperatures increased. Preheating of workpiece by induction heating has been recently reported to enhance the machinability of materials. The latest current work done by Amin et al [5] when he carried out preheated induction heating in end milling of AISI D2 hardened steel using Poly Crystalline Cubic Boron Nitride (PCBN) inserts. He observed that preheated machining of the material leads to surface roughness values well below 0.4 μm, such that the operations of grinding as well as polishing can be avoided at the higher cutting speeds. He added that preheated machining has been able to reduce the amplitude of the lower frequency mode of chatter by almost 4.5 times at the cutting speed of 50 m/min. The primary causes of this stable cutting need to be studied in the perspective of material properties and damping capability of the material in the preheated condition. The primary objective of preheating is to enhance the ductility of the material for easier chip formation and better chip flow over the rake surface of the tool. In addition preheating is expected to improve the tool life and improve surface finish of the machined components. But preheating may lead to softening of the hardened workpiece.. Hence, in the present study an attempt has been made to carry out an investigation in hot machining of end milling operation of AISI D2 hardened steel using induction heating. To discern differences in machinability, the test workpieces were machined with higher range of temperature from 250- 450 °C. IIUM Press Amin, A. K. M. Nurul Adesta, Erry Yulian Triblas Ali, Mohammad Yeakub 2011 Book Chapter PeerReviewed application/pdf en http://irep.iium.edu.my/23584/4/chp5.pdf Amin, A. K. M. Nurul and Lajis, M. A. and Karim, A.N. Mustafizul (2011) Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel. In: Advanced Machining Towards Improved Machinability of Difficult-to-Cut Materials. IIUM Press, Kuala Lumpur, Malaysia, pp. 35-42. ISBN 9789674181758 http://research.iium.edu.my
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Amin, A. K. M. Nurul Lajis, M. A. Karim, A.N. Mustafizul Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel
description	With the advent of several advanced difficult-to-cut materials, and with the availability of heat resistant tool materials has posed a great challenge in industries. Hardened steel is one of these difficult-to-cut materials. During the last few decades numerous studies have been conducted to improve the machinability of these materials and many large organizations have invested considerably in exploring and developing new techniques to minimize machining costs of these materials while maintaining their quality requirements. The benefits for the manufacture of components from hardened steel are substantial in terms of reduced machining costs and lead times, in comparison to the more traditional route which involves machining in the annealed state, heat treatment, grinding or electrical discharge machining (EDM), and manual finishing [1]. Recent advances in cutting tool and machine tool technologies have opened up new opportunities for investigation in machining hard materials and especially for bulk removal of material. For these reasons the growing interest for hot machining process is being developed in industry. In this method work-piece is softened by heating and thereby shear strength is reduced [2]. The technology of hot machining is not new. Previous generations of this technology employed low-grade heat sources such as flame, electrical resistance, induction and plasma arcs [3]. Ozler et al. [4] integrated plasma gas heating in turning of austenitic manganese steel and he noticed that tool life increases when heating temperatures increased. Preheating of workpiece by induction heating has been recently reported to enhance the machinability of materials. The latest current work done by Amin et al [5] when he carried out preheated induction heating in end milling of AISI D2 hardened steel using Poly Crystalline Cubic Boron Nitride (PCBN) inserts. He observed that preheated machining of the material leads to surface roughness values well below 0.4 μm, such that the operations of grinding as well as polishing can be avoided at the higher cutting speeds. He added that preheated machining has been able to reduce the amplitude of the lower frequency mode of chatter by almost 4.5 times at the cutting speed of 50 m/min. The primary causes of this stable cutting need to be studied in the perspective of material properties and damping capability of the material in the preheated condition. The primary objective of preheating is to enhance the ductility of the material for easier chip formation and better chip flow over the rake surface of the tool. In addition preheating is expected to improve the tool life and improve surface finish of the machined components. But preheating may lead to softening of the hardened workpiece.. Hence, in the present study an attempt has been made to carry out an investigation in hot machining of end milling operation of AISI D2 hardened steel using induction heating. To discern differences in machinability, the test workpieces were machined with higher range of temperature from 250- 450 °C.
author2	Amin, A. K. M. Nurul
author_facet	Amin, A. K. M. Nurul Amin, A. K. M. Nurul Lajis, M. A. Karim, A.N. Mustafizul
format	Book Chapter
author	Amin, A. K. M. Nurul Lajis, M. A. Karim, A.N. Mustafizul
author_sort	Amin, A. K. M. Nurul
title	Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel
title_short	Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel
title_full	Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel
title_fullStr	Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel
title_full_unstemmed	Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel
title_sort	tool wear and surface roughness aspects in heat assisted end milling of aisi d2 hardened steel
publisher	IIUM Press
publishDate	2011
url	http://irep.iium.edu.my/23584/ http://irep.iium.edu.my/23584/ http://irep.iium.edu.my/23584/4/chp5.pdf
first_indexed	2023-09-18T20:35:37Z
last_indexed	2023-09-18T20:35:37Z
_version_	1777409025794637824

Tool wear and surface roughness aspects in heat assisted end milling of AISI D2 hardened steel

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