Surface integrity analysis when milling ultrafine-grained steels

This paper quantifies the effects of milling conditions on surface integrity of ultrafine-grained steels. Cutting speed, feed rate and depth of cut were related to microhardness and microstructure of the workpiece beneath machined surface. Low-carbon alloyed steel with 10.8 µm (as-received) and 1.7 µm (ultrafine) grain sizes were end milled using the down-milling and dry condition in a CNC machining center. The results show ultrafine-grained workpiece preserves its surface integrity against cutting parameters more than the as-received material. Cutting speed increases the microhardness while depth of cut deepens the hardened layer of the as-received material. Also, deformations of microstructure following feed rate direction were observed in workpiece subsurface.

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

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.