Determination of maximum depth of cut in 1018 steel and 6061 T6 aluminum with M42 high speed steel tools
Keywords:
Depth of cut, Roughing, M42 high speed steel, Milling, Machining, 1018 steel, 6061 T6 aluminumAbstract
The objective of this research work is to define the maximum depth of cut that can be applied for the roughing operation in the milling process. This research study focuses on the use of 1018 steel and 6061 T6 aluminum, both of them of a high level of machinability and widely used in these processes, using economical tools such as M42 high speed steel, in diameters of 3.18, 4.76, 6.35 and 9.53 mm. The purpose of this is to maximize the productivity of the mentioned process, with its consequent time optimization and cost reduction. The methodology applied is design of experiments with a single factor, n levels (since this was defined by each tool) and 5 replicates. In this case, the factor is the depth cut and the levels are the different values assigned to the mentioned factor. With this, it was possible to find a maximum depth of cut for each tool diameter in function of the material strength of the tool, which is directly proportional to the corresponding cross-section area. The new aspect of this is that it has documented the behavior of the tools in combination with the machining of the raw material mentioned above to obtain maximum exploitation of these. Finally, we add the feed factor with two levels: low (0.05 mm/tooth) and high (0.1 mm/tooth), to the one factor experiments initially considered, to make this work more complete. This results in an indispensable physical-mathematical relationship in the determination of the maximum depth of cut. The involved variables in the resulting equation are the maximum depth of cut and the recommended feed, which are mutually dependent. If the feed is reduced, it can increase the depth of cut proportionally and vice versa.
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