Experimental investigation and optimisation of the micro milling process of hardened hot-work tool steel

In the past few decades, demand for precise miniature components has grown significantly. Modern production technologies required for the production of such components, including micro milling, have become extensively researched areas. In spite of the intensive research in this field, there are still many topics and aspects that merit investigation. Through a systematic series of experiments, this paper analyses the special characteristics of micro milling including cutting forces, vibrations, burr formation, and surface quality. A 5-axis micromachining centre with 60.000 rpm maximum spindle speed was used for the experiments carried out in the scope of this paper, and the machining of hardened hot-work tool steel (AISI H13) with a hardness of 50 HRC was investigated in detail. Also, a special measurement environment was prepared in order to collect machining data. Based on the results of the experiments, a power regression prediction model for cutting forces was created. As part of the analysis in the scope of the experiments, fast Fourier transformation was carried out in order to analyse the dynamic characteristics of the micro milling process, and to determine dominant frequencies. In addition, an analysis of variance (ANOVA) was applied to extensively analyse the main effects and interactions of different cutting parameters on different characteristics. Based on the investigations carried out in a comprehensive parameter range, an optimal parameter combination was also determined. The results of the experiments introduced in this paper contribute to a deeper understanding of the micro milling process, and this research provides information directly applicable in the industry.