Chip morphology analysis in high-speed end milling for D2 hardened steel.

Machining hard materials in high-speed machining is a knowledge area that needs further investigation due to its promoting contribution to machining knowledge and its advantages in reducing time to the market. Chips as one of the tangible outputs can explain many aspects of the machining processes. This research aims to study the chip morphology during high-speed end milling of hardened steel AISI D2. To achieve the study's objective, a set of experiments were conducted to analyze the chip morphology on hardened steel AISI D2 in high-speed end milling at different cutting parameters. The effect of various levels of cutting speed (from 120 to 240 mm/min), feed rate (from 0.05 to 0.15 mm/rev), and depth of cut (from 0.10 to 0.20 mm) were analyzed and investigated. The image of chips collected is examined and investigated utilizing Scanning Electron Microscope (SEM). The results show that the cutting speed and feed rate are the most influential independent factors on the final chip formation in high-speed end milling of hardened steel AISI D2. [ABSTRACT FROM AUTHOR]