INVESTIGATION ON HARDENED STEEL MILLING WITH MICRO-END MILL

Tool wear and breakage of the micro-milling tool is an important problem for high speed machining of hardened steel die and mould. Dry milling of S136 hardened steel is carried out using TiA1N coated carbide micro-end mill (Ф2 mm). The effect of cutting speed, feed per tooth and radial depth of cut on cutting force is analyzed. Cutting parameters adapting to dry machining and strategy optimized for higher rate of material removal with lower cutting force are attained. Results of SEM observation show that the main failure patterns of micro-end mill are breakage of tool tip, wear and drop-off of surface coating, micro-chipping, and breakage of flank.