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Tribological effects of micromilling of hardened AISI D2 steel on tool wear and top burr formation

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Abstract

The study of micromilling of quenched and tempered AISI D2 steel is of utmost importance due to the accelerated wear of the micromilling cutting tool edge that intensifies the formation of top burrs, which is detrimental to the micromilled surfaces because it requires further surface finishing. In this work, the effect of tooth feed per tooth and axial depth of cut on machining forces and top burr formation after dry micromilling of slots in quenched and tempered AISI D2 steel was evaluated. The results show that the passive force is approximately 32% higher than the radial and feed forces. Regarding burr formation, axial depth of cut was the most relevant parameter. Doubling axial depth of cut burr height increased by approximately 400%. Increasing feed per tooth reduces burr formation. The down cutting direction presented top burr heights approximately 23% higher when compared with up cutting. Attrition was the predominant tool wear mechanisms. Tool wear increases progressively with machining length raising the micromilling force components, which leads to rounding and increasing the radius of the cutting edge. Consequently, a negative rake angle is generated, inducing size effect and intensifying the material plowing mechanism.

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Acknowledgements

The authors are grateful to the Graduate Program in Mechanical Engineering, Universidade Federal de Minas Gerais and the Brazilian research agencies CAPES, CNPq, and FAPEMIG for financial support.

Funding

This study was partly financed in part by the Coordenao de Aperfeioamento de Pessoal de Nvel Superior — Brasil (CAPES) — Finance Code 001.

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Authors and Affiliations

  1. Mechanical Engineering Graduate Program, Universidade Federal de Minas Gerais, Av. Antônio Carlos, 6627. Campus Pampulha, Belo Horizonte, Minas Gerais, 31270-901, Brazil

    Anderson Júnior dos Santos, Diogo Azevedo de Oliveira, Juan Carlos Campos Rubio, Alexandre Mendes Abrão & Marcelo Araújo Câmara

  2. Department of Materials Engineering, Federal Center for Technological Education of Minas Gerais, Av. Amazonas, 5253, Nova Suiça, Belo Horizonte, Minas Gerais, 30421-169, Brazil

    Anderson Júnior dos Santos

  3. Department of Urban Engineering, Federal University of Ouro Preto, University Campus of Morro Do Cruzeiro, S/N, Ouro Preto, Minas Gerais, 35400-000, Brazil

    Bárbara Cristina Mendanha Reis

  4. Industrial Engineering Graduate Program, Universidade Federal de Minas Gerais, Av. Antônio Carlos, 6627. Campus Pampulha, Belo Horizonte, Minas Gerais, 31270-901, Brazil

    Natália Fernanda Santos Pereira

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  1. Anderson Júnior dos Santos
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Contributions

Anderson Júnior dos Santos performed the micromilling test, scanning electron microscopy, and profilometry tests and wrote the main text. Bárbara Cristina Mendanha Reis editing and proofreading the article, Natália Fernanda Santos Pereira contributed to the data analysis, Diogo Azevedo de Oliveira article review, Alexandre Mendes Abrão article review, Juan Carlos Campos Rubio article review, and Marcelo Araújo Câmara is the leader of the research team and contributed to the analysis of the results and review of the article.

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Correspondence to Anderson Júnior dos Santos.

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dos Santos, A.J., Reis, B.C.M., Pereira, N.F.S. et al. Tribological effects of micromilling of hardened AISI D2 steel on tool wear and top burr formation. Int J Adv Manuf Technol 127, 5327–5341 (2023). https://doi.org/10.1007/s00170-023-11819-x

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