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Tool life, surface roughness and cutting force in dry face milling of VP100 mold steel
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DOI：10.1007/s00170-026-18658-6.png)
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Abstract
En 中文
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.
Keywords:
VP100 mold steel
Dry face milling
PVD-coated carbide tools
Tool wear
Surface roughness
Cutting force
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