Lajis, M. A. and Amin, A. K. M. Nurul and Karim, A.N. Mustafizul and Ginta, Turnad Lenggo
(2011)
Modeling in preheated machining of AISI D2 hardened steel.
In:
Advanced Machining Towards Improved Machinability of Difficult-to-Cut Materials.
IIUM Press, Kuala Lumpur, Malaysia, pp. 43-48.
ISBN 9789674181758
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Abstract
Tool life prediction plays an important role in modern industry for sustainable manufacturing
and product design. The productivity of a machining system and machining cost, as well as
quality and integrity of the machined surface strongly depend on tool wear and tool life. Sudden
failure of cutting tools leads to loss of productivity, rejection of parts and consequential
economic losses [1].
The advent of several advanced difficult-to-cut materials such as the heat resistant tool steels has
posed a great challenge in their machining. During the last few decades numerous studies have
been conducted to improve the machinability of these materials and many large organizations
have invested considerably in exploring and developing new techniques to minimize machining
costs of these materials while maintaining their quality requirements. The benefits for the
manufacture of components from hardened steel are substantial in terms of reduced machining
costs and lead times, in comparison with the more traditional route which involves machining in
the annealed state, heat treatment, grinding or electrical discharge machining (EDM), and
manual finishing [2]. Recent advances in cutting tool and machine tool technologies have opened
up new opportunities for investigation in machining hard materials and especially for bulk
removal of material. Preheating of workpiece by induction heating has been recently reported to
enhance the machinability of materials. The latest work done by Amin et al [3] were carried out
with induction heating in end milling of AISI D2 hardened steel using Poly Crystalline Cubic
Boron Nitride (PCBN) inserts. They observed that preheated machining of the material leads to
surface roughness values well below 0.4 μm, such that the operations of grinding as well as
polishing can be avoided at the higher cutting speeds. They added that preheated machining was
able to reduce the amplitude of the lower frequency mode of chatter by almost 4.5 times at the
cutting speed of 50 m/min. It was also established by several earlier studies [4-7] that preheating
had great potential in lowering chatter. The primary causes of this stable cutting need to be
studied in the perspective of material properties and damping capability of the material in the preheated condition. The primary objective of preheating is to enhance the ductility of the
material for easier chip formation and better chip flow over the rake surface of the tool. In
addition preheating is expected to improve the tool life and improve surface finish of the
machined components. But preheating may lead to softening of the hardened workpiece. In the
earlier study by Amin, et al [3], preheating temperature was in between 100-150 °C and this
might not substantially change the hardness of the material. Hence, in the present study an
attempt has been made to carry out an investigation in hot machining of end milling operation of
AISI D2 hardened steel using induction heating. To discern differences in machinability, the test
workpieces were machined with higher range of temperature from 250-450 °C.
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