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Influence of feed and cutting-edge radius on tool wear, surface roughness, and electric current in milling of VP20TS steel

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Abstract

Tool steels are widely used in the plastics transformation industry, mainly as raw material to produce molds and dies. In this work, the influence of feed and rounding of the cutting tool edge in the machining of VP20TS steel will be investigated. For this, the wear of the cutting tool will be analyzed with the aid of optical microscopy, scanning electron microscopy, and energy-dispersive x-ray spectroscopy, the roughness of the machined surface will be evaluated through the parameter Ra, and the electric current required by the machine tool will be monitored by means of Hall effect sensors attached to the main power cables. The results obtained showed that the cutting tool wear was attenuated with the use of rβ = 0.03 mm, with adhesion being the predominant wear mechanism. The increase in feed influenced the decrease in wear. The machined surface roughness decreased when the tool with the highest cutting-edge radius value was used. Low-cost system used to monitor the electrical current required by the machine was sensitive to changes in feed and cutting-edge preparation. For higher values of feed and cutting-edge radius, higher values of electric current were required, indicating that edges prepared with larger values of radius generate greater cutting forces.

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Acknowledgements

The authors would like to thank Federal University of Piauí, CAPES, and Villares Metals.

Funding

This study was partly funded by the Federal University of Piauí (UFPI) and State University of Campinas (Unicamp) – grant reference 5102—FUNCAMP.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Campus Ministro Petrônio Portella, Federal University of Piauí - UFPI, Universitária Ave., Teresina, Piauí, 64049-550, Brazil

    Marcos Guilherme Carvalho Braulio Barbosa & Patrick Abreu de Oliveira

  2. Postgraduate Program in Materials Science and Engineering, Campus Ministro Petrônio Portella, Federal University of Piauí (UFPI), Teresina, PI, Brazil

    Marcos Guilherme Carvalho Braulio Barbosa & Patrick Abreu de Oliveira

  3. Department of Manufacturing and Materials Engineering, School of Mechanical Engineering, University of Campinas - UNICAMP, 200 Mendeleyev St., Barão Geraldo, Campinas, São Paulo, 13083-860, Brazil

    Amauri Hassui

  4. Department of Mechanic, Federal Institute of Maranhão - IFMA, Road MA-381 KM 0, Pedreiras, Maranhão, 65725-000, Brazil

    Wênio Fhará Alencar Borges

Authors
  1. Marcos Guilherme Carvalho Braulio Barbosa
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  2. Amauri Hassui
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  3. Patrick Abreu de Oliveira
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  4. Wênio Fhará Alencar Borges
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Contributions

M. Barbosa performed the experiments, analysis of results and manuscript writings; A. Hassui proposed the work topic and helped with results analysis; P. de Oliveira contributed to performed the experiments; W. Borges helped manuscript writings.

Corresponding author

Correspondence to Marcos Guilherme Carvalho Braulio Barbosa.

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Barbosa, M.G.C.B., Hassui, A., de Oliveira, P.A. et al. Influence of feed and cutting-edge radius on tool wear, surface roughness, and electric current in milling of VP20TS steel. Int J Adv Manuf Technol 129, 3609–3626 (2023). https://doi.org/10.1007/s00170-023-12526-3

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