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Manufacturing of dies from hardened tool steels by 3-axis micromilling

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Abstract

In this paper the results of an experimental investigation to analyze the machinability of a hardened, carbide-rich cold-work tool steel 1.2379 (approx. 62 HRC) with coated micro end-milling cutters are discussed. Fundamental experiments were performed to determine a cutting-parameter set, which enables an economic manufacturing of dies by 3-axis micromilling with commercially available cemented-carbide tools. The evaluation of the applicability of different tool types is conducted by analyzing the process forces, the tool wear, the surface quality, the material removal rate, and the entire chip volume. Design of experiments was used to significantly reduce the number of experiments and to model the active and passive forces. Concerning the design of tools for the micromilling of such difficult-to-machine materials, it is shown that cemented-carbide tools with robust cutting edges are applicable for this kind of machining. Furthermore, test microstructures were manufactured with the intention of validating the determined cutting-parameter set in combination with the selected tool types. In addition, the dimension and shape accuracy of the microstructures are analyzed.

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Acknowledgments

This artice is based on investigatons of the research project B2 “Machining of molds with filigree structures for sheet-bulk metal forming”, which is kindly supported by the German Research Foundation (DFG) within the SFB/TR 73.

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Authors and Affiliations

  1. Institute of Machining Technology, Technische Universität Dortmund, Baroper Straße 301, 44227, Dortmund, Germany

    Dirk Biermann, Alexander Baschin, Eugen Krebs & Juliane Schlenker

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  1. Dirk Biermann
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  2. Alexander Baschin
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  3. Eugen Krebs
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  4. Juliane Schlenker
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Correspondence to Alexander Baschin.

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Biermann, D., Baschin, A., Krebs, E. et al. Manufacturing of dies from hardened tool steels by 3-axis micromilling. Prod. Eng. Res. Devel. 5, 209–217 (2011). https://doi.org/10.1007/s11740-010-0293-7

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  • DOI: https://doi.org/10.1007/s11740-010-0293-7

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