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Influence of HSM cutting parameters on the surface integrity characteristics of hardened AISI H13 steel

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Abstract

The purpose of this study is to evaluate the influence of the cutting parameters of high-speed machining milling on the characteristics of the surface integrity of hardened AISI H13 steel. High-speed machining has been used intensively in the mold and dies industry. The cutting parameters used as input variables were cutting speed (v c), depth of cut (a p), working engagement (a e) and feed per tooth (f z ), while the output variables were three-dimensional (3D) workpiece roughness parameters, surface and cross section microhardness, residual stress and white layer thickness. The subsurface layers were examined by scanning electron and optical microscopy. Cross section hardness was measured with an instrumented microhardness tester. Residual stress was measured by the X-ray diffraction method. From a statistical standpoint (the main effects of the input parameters were evaluated by analysis of variance), working engagement (a e) was the cutting parameter that exerted the strongest effect on most of the 3D roughness parameters. Feed per tooth (f z ) was the most important cutting parameter in cavity formation. Cutting speed (v c) and depth of cut (a p) did not significantly affect the 3D roughness parameters. Cutting speed showed the strongest influence on residual stress, while depth of cut exerted the strongest effect on the formation of white layer and on the increase in surface hardness.

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Abbreviations

A r :

Real contact area

a p :

Depth of cut, mm

a e :

Working engagement, mm

c h :

Crest height, mm

f z :

Feed per tooth, mm

v c :

Cutting speed, m/min

S a :

Arithmetic mean, μm

S q :

Root-mean-square deviation of the surface, μm

S z :

Ten-point height of the surface, μm

S sk :

Asymmetry of surface deviations about the mean plane

S ku :

Peakedness or sharpness of surface height distributions

S pk :

Reduced summit height, μm

S k :

Core roughness depth, μm

S vi :

Valley fluid retention index

S tr :

Texture aspect ratio

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Acknowledgments

The authors are indebted to Villares Metals for donating the AISI H13 steel, Brasimet for the heat treatments, Sandvik for donating the tools and tool holder, the Institute of Aeronautical Technology (ITA) for conducting preliminary tests, the Brazilian–German Institute of Technology (ITBA) for loaning the use of a Deckel Maho machine tool, the Federal University of Uberlândia (UFU) for the 3D roughness measurements and the Institute for Energy and Nuclear Research (IPEN) for the residual stress measurements.

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Authors and Affiliations

  1. Academic Department of Mechanics, Federal Technological University of Paraná, Curitiba, PR, 80230-901, Brazil

    Daniel Hioki

  2. Faculty of Mechanical Engineering, State University of Campinas, Campinas, SP, 13083-970, Brazil

    Anselmo E. Diniz

  3. Laboratory of Surface Phenomena, Department of Mechanical Engineering, Polytechnic School of the University of São Paulo, São Paulo, SP, 05508-900, Brazil

    Amilton Sinatora

Authors
  1. Daniel Hioki
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  2. Anselmo E. Diniz
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  3. Amilton Sinatora
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Correspondence to Daniel Hioki.

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Technical Editor: Alexandre Abrão.

Appendix

Appendix

This paper analyzed only the influence of the cutting parameter with the strongest statistical effect on the roughness parameter.

See Table 5, 6, 7, 8, 9, 10, 11 and 12.

Table 10 ANOVA of surface hardness
Full size table
Table 11 ANOVA of residual stress
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Table 12 Results of measurements of 3D parameter
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Hioki, D., Diniz, A.E. & Sinatora, A. Influence of HSM cutting parameters on the surface integrity characteristics of hardened AISI H13 steel. J Braz. Soc. Mech. Sci. Eng. 35, 537–553 (2013). https://doi.org/10.1007/s40430-013-0050-x

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  • DOI: https://doi.org/10.1007/s40430-013-0050-x

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