Tool Wear Model And Wear Mechanisms When Machining Tialn Ball End Mill With High Thermal Conductivity Steel (Htcs 150)

The intent of this research is to develop the regression model and optimization focused on the relationship between the cutting parameters and wear performance when machining HTCS-150 by using Response Surface Methodology experimental design. Microscopy analysis was employed to identify surface characteristics. Experimental processes were carried out using Computer Numerical Control milling machine with ranges of cutting speeds of 484-553 m/min, feed rates of 0.31-0.36 mm/tooth, axial depth of cut of 0.1-0.5 mm and constant radial depth of cut of 0.01 mm. The results show that the model that developed adequately represent the process with modeling validation runs within the 90% prediction interval. The combination of cutting parameter for lowest tool wear recorded as 553 m/min cutting speed, 0.36 mm/tooth feed rate and 0.1 mm axial depth of cut. The wear on the cutting tool started at the centre of the flank face before generated to the near upper-contact zone. Dominant wear mechanisms appeared to be coating delamination, abrasion wear, chipping and adhesion wear.