Advertisement

Tool wear in dry helical milling for hole-making in AISI H13 hardened steel

  • Robson Bruno Dutra PereiraEmail author
  • Carlos Henrique Lauro
  • Lincoln Cardoso Brandão
  • João Roberto Ferreira
  • J. Paulo Davim
ORIGINAL ARTICLE
  • 50 Downloads

Abstract

Helical milling is a hole-making process which can be applied to achieve high-quality finished boreholes in hardened steels. Due to the drilling process limitations, which are intensified when applied in hardened steels, the helical milling process can be applied on hole-making tasks in moulds and dies industry, since milling have been widely applied in moulds and dies machining to replace high-cost operations like grinding and electrical discharge machining. However, to succeed in achieving high-quality boreholes in hardened parts, which presents high added value due to previous operations, tool wear in the helical milling of hardened steels should be more investigated. In the present study, dry helical milling tool life tests were conducted in AISI H13 hardened steel parts, varying the cutting velocity. The flank wear on frontal cutting edges was progressively measured through optical microscopy, and SEM/EDS was performed in frontal and peripheral worn cutting edges. The wear occurred progressively in the flank of the frontal cutting edges with adhesion and oxidation as main wear mechanisms. In the peripheral edges, coating loss, and adhesion of workpiece material in the tool clearance surface were observed, besides fracture in the tool nose flank with the highest cutting velocity. A nested ANOVA was performed to evaluate the burr height in the borehole exit. The tool life stage was statistically significant in the burr height.

Keywords

Helical milling Tool wear Tool life Hardened steel Burr formation 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

The authors gratefully acknowledge the Brazilian National Council for Scientific and Technological Development (CNPq), the Coordination of Superior Level Staff Improvement (CAPES), and the Research Support Foundation of the State of Minas Gerais (FAPEMIG) for supporting this research. The authors gratefully acknowledge the Foundation for Science and Technology of Portugal (FCT) for supporting the project Sustainable and intelligent manufacturing by machining (FAMASI), process POCI-01-0145-FEDER-031556. The first author acknowledges CAPES for the PDSE grant, process number 88881.133263/2016-01, the Centre for Mechanical Technology and Automation-TEMA, and Department of Mechanical Engineering of Univ ersity of Aveiro for supporting this research.

References

  1. 1.
    Brinksmeier E, Fangmann S, Meyer I (2008) Orbital drilling kinematics. Prod Eng 2(3):277–283CrossRefGoogle Scholar
  2. 2.
    Denkena B, Boehnke D, Dege JH (2008) Helical milling of CFRP–titanium layer compounds. CIRP J Manuf Sci Technol 1(2):64–69CrossRefGoogle Scholar
  3. 3.
    Iyer R, Koshy P, Ng E (2007) Helical milling: an enabling technology for hard machining precision holes in AISI D2 tool steel. Int J Mach Tools Manuf 47(2):205–210CrossRefGoogle Scholar
  4. 4.
    Zhao Q, Qin X, Ji C, Li Y, Sun D, Jin Y (2015) Tool life and hole surface integrity studies for hole-making of Ti6Al4V alloy. Int J Adv Manuf Technol 79(5–8):1017–1026CrossRefGoogle Scholar
  5. 5.
    Sasahara H, Kawasaki M, Tsutsumi M (2008) Helical feed milling with MQL for boring of aluminum alloy. J Adv Mech Des Syst Manuf 2(6):1030–1040CrossRefGoogle Scholar
  6. 6.
    Eguti CCA, Trabasso LG (2014) Design of a robotic orbital driller for assembling aircraft structures. Mechatronics 24(5):533–545CrossRefGoogle Scholar
  7. 7.
    Tönshoff HK, Spintig W, König W, Neises A (1994) Machining of holes developments in drilling technology. CIRP Ann-Manuf Technol 43(2):551–561CrossRefGoogle Scholar
  8. 8.
    Saadatbakhsh MH, Imani H, Sadeghi MH, Farshi SS (2017) Experimental study of surface roughness and geometrical and dimensional tolerances in helical milling of AISI 4340 alloy steel. Int J Adv Manuf Technol 93(9–12):4063–4074CrossRefGoogle Scholar
  9. 9.
    Liu C, Wang G, Dargusch MS (2012) Modelling, simulation and experimental investigation of cutting forces during helical milling operations. Int J Adv Manuf Technol 63(9–12):839–850CrossRefGoogle Scholar
  10. 10.
    Liu J, Chen G, Ji C, Qin X, Li H, Ren C (2014) An investigation of workpiece temperature variation of helical milling for carbon fiber reinforced plastics (CFRP). Int J Mach Tools Manuf 86:89–103CrossRefGoogle Scholar
  11. 11.
    Wang H, Qin X, Li H, Tan Y (2016) A comparative study on helical milling of CFRP/Ti stacks and its individual layers. Int J Adv Manuf Technol 86(5–8):1973–1983CrossRefGoogle Scholar
  12. 12.
    Pereira RBD, Brandão LC, de Paiva AP, Ferreira JR, Davim JP (2017) A review of helical milling process. Int J Mach Tools Manuf 120:27–48CrossRefGoogle Scholar
  13. 13.
    He G, Li H, Jiang Y, Qin X, Zhang X, Guan Y (2015) Helical milling of CFRP/Ti-6Al-4V stacks with varying machining parameters. Trans Tianjin Univ 21(1):56–63CrossRefGoogle Scholar
  14. 14.
    Li H, He G, Qin X, Wang G, Lu C, Gui L (2014) Tool wear and hole quality investigation in dry helical milling of Ti-6Al-4V alloy. Int J Adv Manuf Technol 71(5–8):1511–1523CrossRefGoogle Scholar
  15. 15.
    Qin X, Zhang X, Li H, Rong B, Wang D, Zhang H, Zuo G (2014) Comparative analyses on tool wear in helical milling of Ti-6Al-4V using diamond-coated tool and TiAlN-coated tool. J Adv Mech Des Syst Manuf 8(1):1–14CrossRefGoogle Scholar
  16. 16.
    Camargo JC, Dominguez DS, Ezugwu EO, Machado ÁR (2014) Wear model in turning of hardened steel with PCBN tool. Int J Refract Met Hard Mater 47:61–70CrossRefGoogle Scholar
  17. 17.
    Wang B, Liu Z (2016) Cutting performance of solid ceramic end milling tools in machining hardened AISI H13 steel. Int J Refract Met Hard Mater 55:24–32CrossRefGoogle Scholar
  18. 18.
    An Q, Wang C, Xu J, Liu P, Chen M (2014) Experimental investigation on hard milling of high strength steel using PVD-AlTiN coated cemented carbide tool. Int J Refract Met Hard Mater 43:94–101CrossRefGoogle Scholar
  19. 19.
    Hintze W, Steinbach S, Susemihl C, Kähler F (2018) HPC-milling of WC-Co cemented carbides with PCD. Int J Refract Met Hard Mater 72:126–134CrossRefGoogle Scholar
  20. 20.
    Arruda ÉM, Brandão LC (2018) Performance study of multilayer carbide tool in high-speed turning of API 5L X70 pipeline steel using a cold air system. Int J Adv Manuf Technol 94(1–4):85–103CrossRefGoogle Scholar
  21. 21.
    Mao C, Ren Y, Gan H, Zhang M, Zhang J, Tang K (2015) Microstructure and mechanical properties of cBN-WC-Co composites used for cutting tools. Int J Adv Manuf Technol 76(9–12):2043–2049CrossRefGoogle Scholar
  22. 22.
    Wang X, Hwang KS, Koopman M, Fang ZZ, Zhang L (2013) Mechanical properties and wear resistance of functionally graded WC–Co. Int J Refract Met Hard Mater 36:46–51CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Robson Bruno Dutra Pereira
    • 1
    Email author
  • Carlos Henrique Lauro
    • 1
  • Lincoln Cardoso Brandão
    • 1
  • João Roberto Ferreira
    • 2
  • J. Paulo Davim
    • 3
  1. 1.Department of Mechanical Engineering-Industrial EngineeringFederal University of São João del Rei (UFSJ)São João del ReiBrazil
  2. 2.Institute of Industrial Engineering and ManagementFederal University of Itajubá (UNIFEI)ItajubáBrazil
  3. 3.Department of Mechanical EngineeringUniversity of Aveiro, Campus SantiagoAveiroPortugal

Personalised recommendations