High-speed machining of cast iron and alloy steels for die and mold manufacturing

This paper gives a brief overview of HSC technology and presents current progress in high performance machining of cast iron and alloy steels used in die and mold manufacturing. This work covers: (a) theoretical and experimental studies of tool failure and tool life in high-speed milling of hard materials, (b) optimization of CNC programs by adjusting spindle RPM and feed rate (program OPTIMILL) to maintain nearly constant chip load in machining sculptured surfaces, and (c) prediction of chip flow, stresses and temperatures in the cutting tool as well as residual stresses in the machine surface layer. Experimental studies are conducted using a 4-axis high-speed milling machine. Tool materials evaluated include carbides, coated carbides, and PCBN. Workpiece materials investigated include H-13 at 46 HRC, P-20 at 20-40 HRC and cast iron.