HSM strategy study for hardened die and mold steels manufacturing based on the mechanical and thermal load reduction strategy

The paper discussed cutter-work engagement situation hidden behind the mechanical and thermal load effect on cutting edges during high speed hard machining process. The engagement situation was investigated in great detail using experimental and geometrical analytic measures. Experiments were conducted using AlTiN-coated micro-grain carbide end mill cutters to cut hardened die steel. On the basis, a general high speed hard machining strategy, which aimed at eliminating excessive engagement situation during high-speed machining (HSM) hard machining, was proposed. The strategy includes the procedures to identify prone-to-overload areas where excessive engagement situation occurs and then to create a reliable tool path, which has the effect of cutting load reduction to remove the prone-to-overload areas.