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<p>Dry face milling of VP100 mold steel is relevant to polymer injection mold manufacturing, but it remains unclear whether the tool condition that maximizes productive tool life also provides favorable surface roughness and feed-direction mechanical loading under the same dry cutting domain. This study compares uncoated, TiN-, AlTiN- and AlTiN/TiSiXN-coated cemented carbide inserts. A two-level full factorial design varied cutting speed (<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\varvec{V}_{\varvec{c}}\)</EquationSource> </InlineEquation> = 125 and 175 m/min), feed per tooth (<InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\varvec{f}_{\varvec{z}}\)</EquationSource> </InlineEquation> = 0.10 and 0.20 mm/tooth) and axial depth of cut (<InlineEquation ID="IEq3"> <EquationSource Format="TEX">\(\varvec{a}_{\varvec{p}}\)</EquationSource> </InlineEquation> = 0.70 and 1.00 mm), with three replicates per combination. Tool-life monitoring, longitudinal roughness measurements, force acquisition, SEM/EDS wear characterization and global statistical models with ANOVA-type tests, estimated marginal means and Tukey-adjusted contrasts were used to evaluate material removal volume (MRV), tool end-of-life time (<InlineEquation ID="IEq4"> <EquationSource Format="TEX">\(\varvec{t}_{{\textbf {EOL}}}\)</EquationSource> </InlineEquation>), root-mean-square roughness (<InlineEquation ID="IEq5"> <EquationSource Format="TEX">\(\varvec{R}_{\varvec{q}}\)</EquationSource> </InlineEquation>) and feed-direction force (<InlineEquation ID="IEq6"> <EquationSource Format="TEX">\(\varvec{F}_{\varvec{x}}\)</EquationSource> </InlineEquation>). AlTiN and AlTiN/TiSiXN substantially increased MRV and <InlineEquation ID="IEq7"> <EquationSource Format="TEX">\(\varvec{t}_{{\textbf {EOL}}}\)</EquationSource> </InlineEquation> compared with the uncoated and TiN-coated tools. The highest observed MRV was obtained with AlTiN/TiSiXN at <InlineEquation ID="IEq8"> <EquationSource Format="TEX">\(\varvec{V}_{\varvec{c}}\)</EquationSource> </InlineEquation> = 125 m/min, <InlineEquation ID="IEq9"> <EquationSource Format="TEX">\(\varvec{f}_{\varvec{z}}\)</EquationSource> </InlineEquation> = 0.20 mm/tooth and <InlineEquation ID="IEq10"> <EquationSource Format="TEX">\(\varvec{a}_{\varvec{p}}\)</EquationSource> </InlineEquation> = 1.00 mm, reaching 266.7 cm<InlineEquation ID="IEq11"> <EquationSource Format="TEX">\(^3\)</EquationSource> </InlineEquation>; under the same condition, AlTiN reached 193.3 cm<InlineEquation ID="IEq12"> <EquationSource Format="TEX">\(^3\)</EquationSource> </InlineEquation>. Flank wear governed tool end of life, with abrasion as the dominant mechanism, accompanied by adhesion, localized chipping and local coating degradation. However, the highest-MRV condition did not provide the lowest <InlineEquation ID="IEq13"> <EquationSource Format="TEX">\(\varvec{R}_{\varvec{q}}\)</EquationSource> </InlineEquation> or <InlineEquation ID="IEq14"> <EquationSource Format="TEX">\(\varvec{F}_{\varvec{x}}\)</EquationSource> </InlineEquation>. Tool selection should therefore be treated as a productivity-surface-force compromise: AlTiN/TiSiXN is favored when productive tool life is the priority, whereas AlTiN remains competitive when lower roughness and feed-direction loading are also relevant.</p>

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Tool life, surface roughness and cutting force in dry face milling of VP100 mold steel

  • 期刊论文

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  • 发表日期：

    2026年7月10日

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  • Danilo S. Oliveira,
  • Jackson P. B. Souza,
  • Rhander Viana,
  • Alberto J. Alvares

摘要

Dry face milling of VP100 mold steel is relevant to polymer injection mold manufacturing, but it remains unclear whether the tool condition that maximizes productive tool life also provides favorable surface roughness and feed-direction mechanical loading under the same dry cutting domain. This study compares uncoated, TiN-, AlTiN- and AlTiN/TiSiXN-coated cemented carbide inserts. A two-level full factorial design varied cutting speed ( \(\varvec{V}_{\varvec{c}}\) = 125 and 175 m/min), feed per tooth ( \(\varvec{f}_{\varvec{z}}\) = 0.10 and 0.20 mm/tooth) and axial depth of cut ( \(\varvec{a}_{\varvec{p}}\) = 0.70 and 1.00 mm), with three replicates per combination. Tool-life monitoring, longitudinal roughness measurements, force acquisition, SEM/EDS wear characterization and global statistical models with ANOVA-type tests, estimated marginal means and Tukey-adjusted contrasts were used to evaluate material removal volume (MRV), tool end-of-life time ( \(\varvec{t}_{{\textbf {EOL}}}\) ), root-mean-square roughness ( \(\varvec{R}_{\varvec{q}}\) ) and feed-direction force ( \(\varvec{F}_{\varvec{x}}\) ). AlTiN and AlTiN/TiSiXN substantially increased MRV and \(\varvec{t}_{{\textbf {EOL}}}\) compared with the uncoated and TiN-coated tools. The highest observed MRV was obtained with AlTiN/TiSiXN at \(\varvec{V}_{\varvec{c}}\) = 125 m/min, \(\varvec{f}_{\varvec{z}}\) = 0.20 mm/tooth and \(\varvec{a}_{\varvec{p}}\) = 1.00 mm, reaching 266.7 cm \(^3\) ; under the same condition, AlTiN reached 193.3 cm \(^3\) . Flank wear governed tool end of life, with abrasion as the dominant mechanism, accompanied by adhesion, localized chipping and local coating degradation. However, the highest-MRV condition did not provide the lowest \(\varvec{R}_{\varvec{q}}\) or \(\varvec{F}_{\varvec{x}}\) . Tool selection should therefore be treated as a productivity-surface-force compromise: AlTiN/TiSiXN is favored when productive tool life is the priority, whereas AlTiN remains competitive when lower roughness and feed-direction loading are also relevant.