Development of tool life prediction model for PCBNinserts during the high speed end milling of AISI H13hardened tool steel

This paper presents the result of an experimental investigation on tool wear of PCBN tool insert during the high speed end milling of AISI H13 tool steel under dry cutting condition. Sufficient numbers of experiment were run based on the central composite design (CCD) concept of response surface methodology (RSM) in order to generate tool life data. An empirical second order quadratic model in terms of cutting speed, feed and axial depth of cut has been developed for the effective prediction of tool life under particular cutting condition. The adequacy of the model has been verified by ANOVA at 95% confidence interval. From the model it is clear that cutting speed possesses the most dominating effect over tool life followed by feed and axial depth of cut. An increasing cutting speed, feed and axial depth of cut will result in decreasing tool life.

[1]  Gérard Poulachon,et al.  Wear behavior of CBN tools while turning various hardened steels , 2004 .

[2]  Kuang-Hua Fuht,et al.  A Proposed statistical model for surface quality prediction in end-milling of A1 alloy , 1995 .

[3]  R. T. Coelho,et al.  An Investigation of the Wear Mechanisms of Polycrystalline Cubic Boron Nitride (PCBN) Tools when End Milling Hardened Steels at Low/Medium Cutting Speeds , 2001 .

[4]  S. Saikumar,et al.  Parameter Selection Based on Surface Finish in High-Speed End-Milling Using Differential Evolution , 2006 .

[5]  Imtiaz Ahmed Choudhury,et al.  Performance of P10 TiN coated carbide tools when end milling AISI H13 tool steel at high cutting speed , 2004 .

[6]  Imtiaz Ahmed Choudhury,et al.  Application of Taguchi method in the optimization of end milling parameters , 2004 .

[7]  R. Komanduri,et al.  Machining of Hard Materials , 1984 .

[8]  Taylan Altan,et al.  High-speed machining of cast iron and alloy steels for die and mold manufacturing , 2000 .

[9]  Safian Sharif,et al.  Cutting Force Predictions Models in End MillingTitanium Alloy Ti-6Al-4V , 2006 .

[10]  M. Zheng,et al.  On the machining characteristics of H13 tool steel in different hardness states in ball end milling , 2003 .

[11]  Hasan Kurtaran,et al.  Application of response surface methodology in the optimization of cutting conditions for surface roughness , 2005 .

[12]  M. A. El Baradie,et al.  Modelling of cutting force in end milling Inconel 718 , 1996 .

[13]  Ajay P. Malshe,et al.  Tool wear and machining performance of cBN–TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel , 2006 .

[14]  M. Alauddin,et al.  Optimization of surface finish in end milling Inconel 718 , 1996 .

[15]  S. M. Wu.  Tool-Life Testing by Response Surface Methodology—Part 2 , 1964 .