Experimental investigation for optimisation of process parameters during milling of D2 tool steel

Abstract

newline quotIn present scenario, Die and mould making industries have major challenging task to improve quality with minimum production time. D-grade high carbon and high chromium AISI D2 tool steel is highly used in the manufacture of rolling die, deep drawing die and various cold forming dies due to excellent wear characteristics and deep hardening. AISI D2 tool steel has been used as work material for the current experimentation purpose. Machining of hardened tool steel is challenging task due to extreme hardness, high temperature and tool wear. Numerous studies have been done on different coated tools such as CrN, TiN, AlCrN, AlTiN etc. AlCrN coated tool has higher hot-hardness and superior oxidation resistance. The present work gives the details of experimental investigation on AISI D2 tool steel using AlCrN coated end mill tool. newlineThe main objective of the present research work is to investigate the effects of the various end milling process parameters on the output responses like cutting force and surface roughness. The working ranges and levels of the milling process parameters have been found using one variable at a time (OVAT) approach. The response surface methodology (RSM) has been used to develop the empirical models for response characteristics. In present research work, quadratic model has been suggested for all responses. ANOVA test has been carried out for checking adaptability of models. Cutting speed and width of cut have been identified as significant parameters for the prediction of cutting force. For prediction of surface roughness value feed rate, axial depth of cut and cutting speed have been identified as significant parameters. It has been found that feed rate exerts maximum effect in reduction of surface roughness followed by depth of cut and cutting speed. newlineThe response surface methodology has also been utilized to optimise the various process parameters during machining of AISI D2 tool steel using AlCrN coated end mill tool. The influence of different process parameters namely cutting