Interaction Effects of Cutting Parameters on Surface Roughness in Hard Milling of AISI D2 Tool Steel
Downloads
This paper investigates the effects of cutting speed, feed rate, and depth of cut on the surface roughness (Ra) in the dry hard milling of AISI D2 steel (60–62 HRC) using carbide inserts. A Box–Behnken experimental design was applied to evaluate the interaction effects among the machining parameters. The experimental results clearly reveal the influence trends and interaction relationships of cutting conditions on surface roughness. At a depth of cut of 0.15 mm, lower surface roughness values were obtained when the cutting speed ranged from 105 to 120 m/min and the feed rate was maintained between 0.10 and 0.11 mm/tooth. For a feed rate of 0.15 mm/tooth, improved surface quality was achieved with cutting speeds of 108–120 m/min and depths of cut of 0.10–0.15 mm. Furthermore, when the cutting speed was fixed at 100 m/min, feed rates of 0.10–0.11 mm/tooth combined with all investigated depths of cut produced lower Ra values. These findings provide useful technical guidelines for future studies and practical applications in hard milling processes.
Halil C- alıskan, Cahit Kurbanoglu, Peter Panjan, Miha Cekada, Davorin Kramar, Wear behavior and cutting performance of nanostructured hard coatings on cemented carbide cutting tools in hard milling, Tribology International 2013, 62, 215–222, Doi: 10.1016/j.triboint.2013.02.035.
Yanhao Huo, Ying Niu, Zhipeng Sun, Yuanxiao Li, Jingjing Niu,Surface/subsurface damage
mechanisms and inhibition strategies in machining of hard and brittle materials: A systematic review, Surfaces and Interfaces,54, 2024,
,https://doi.org/10.1016/j.surfin.2024.105088.
Khaider Bouacha, Mohamed Athmane Yallese, Tarek Mabrouki, Jean-François Rigal. Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with CBN tool. Int. Journal of Refractory Metals & Hard Materials 2010, 28, 349–361.
Doi: 10.1016/j.ijrmhm.2009.11.011.
J. Paulo Davim, Machining of Hard Materials, Springer-Verlag London Limited, 2011.
https://doi.org/10.1007/978-1-84996-450-0.
Dong, P. Q., Duc, T. M., & Long, T. T. (2019). Performance Evaluation of MQCL Hard Milling of SKD 11 Tool Steel Using MoS2 Nanofluid. Metals, 9(6), 658. https://doi.org/10.3390/met9060658
T. V. Do and N. A. V. Le. Development of a Multi-Objective Optimization Model for the Hard Turning of SKD11 Steel with Nanofluid-Al₂O₃ Minimum Quantity Lubrication Using RSM and PSO, Eng. Technol. Appl. Sci. Res., vol. 15, no. 4, pp. 24897–24903, Aug. 2025.
https://doi.org/10.48084/etasr.11351
Sana Ehsan, Muhammad Asad Ali, Sarmad Ali Khan, Muhammad Sana, Muhammad Yasir, Saqib Anwar, Muhammad Umar Farooq. Understanding the effects of cutting conditions on vibrations, surface integrity, machining temperature and tool wear mechanisms in end milling of AISI D2 Steel, Tribology International, 198, 2024, 109894, https://doi.org/10.1016/j.triboint.2024.109894.
