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Vanadis 4E is a powder metallurgical cold work tool steel which offers very good combination of wear resistance and ductility. It is commonly used in blanking and forming, cold extrusion tooling, powder pressing and knives. In this study, face milling was applied on Vanadis 4E powder metallurgical cold work tool steel with a size of 100 x 80 x 30 mm3 and the effects of cutting parameters on surface roughness and tool wear were investigated during milling. Taguchi L9 (34) orthogonal arrays were used for the experiments and nine tests were performed. Three different coated inserts (CVD/Al2O3-TiCN-TiN coated insert, PVD/TiAlN nanolayer coated insert and PVD/TiB2 coated insert), three different cutting depths (0.3, 0.5 and 0.7 mm), three different cutting speeds (150, 180 and 200 m/min) and three different feeds (0.1, 0.2 and 0.3 mm/tooth) were used in the tests. Surface roughness measurements were made for each test and tool wear measurements were performed for each test by repeating each test six times. Cutting data parameters were optimized by using roughness and wear values and the results were evaluated through signal-to-noise ratio (S/N), analysis of variance (ANOVA) and three-dimensional graphics, after then, mathematical models for surface roughness and tool wear were obtained by using fit regression model. Three verification tests were performed using the optimum parameters after optimization. Verification test results showed that the Taguchi method was successfully applied to optimize the cutting parameters for minimum surface roughness and tool wear in Vanadis 4E milling. [ABSTRACT FROM AUTHOR]

Vanadis 4E is a powder metallurgic tool steel that provides an excellent combination of wear resistance and ductility for high-performance tools, and it is more machinable than AISI D2 tool steel. This study applied grooving on Vanadis 4E powder metallurgic tool steel with the dimensions of 80 × 105 × 35 mm, and during the milling process, investigated the effects of cutting parameters on surface roughness and tool flank wear. Using the Taguchi L9 (34) array, 9 experiments were carried out. In the experiments, uniform carbide end mills with diameters of 12 mm were used as new and sharpened (first usage, first sharpening, second sharpening), and the experiments were performed with three cutting depths (1, 1.5 and 2 mm), three cutting speeds (60, 80 and 100 m/min) and three feed rates (0.02, 0.04 and 0.06 mm/tooth). During the experiments, temperature measurements were made with a thermal camera from the cutting area, and surface roughness and tool wear measurements were made after every one experiment. The cutting parameters were optimized by using the obtained roughness and flank wear values, and the results were analyzed by signal-to-noise ratios, analysis of variance (ANOVA), three-dimensional graphs and thermal images. After optimization, three confirmation experiments were conducted by using the optimum parameters, and the values that were estimated with the Taguchi method and the results of the verification experiments were compared. [ABSTRACT FROM AUTHOR]