Effect of Milling Strategy on the Surface Quality of AISI P20 Mold Steel

Abstract

This paper explores the impact of various milling strategies, including up-milling, down-milling, and hybrid approaches, on the surface roughness of AISI P20 mold steel. The study is methodically divided into three stages to comprehensively understand the effects of these strategies. The first stage involves milling single slots with varying cutting parameters to establish baseline effects. The second stage examines the effects of consistent milling strategies (up-up and down-down) on surface quality. The third stage probes into hybrid strategies (up-down and down-up) to assess their effectiveness. Central to this investigation is not only the type of milling strategy but also how cutting speed and feed rate influence the resultant surface roughness. Our findings indicate that up-milling generally leads to a 22% increase in surface roughness compared to down-milling. This trend is visually verified by surface texture analyses. When comparing consistent strategies, up-up milling tends to produce rougher surfaces than down-down milling by approximately 25%, characterized by distinctive scratches and feed mark overlays. Remarkably, while the hybrid milling strategies do not exhibit significant differences in surface roughness, variations in cutting speed and feed rate play a crucial role. Specifically, at lower speeds, hybrid milling achieves smoother surfaces than the identical double milling mode, while at a cutting speed of 100 m/min, the double mode demonstrates a notable decrease in roughness. Additionally, this study introduces a color mapping simulation for machined pockets, validated by experimental results, to predict surface roughness based on the strategic history of milling, thereby offering valuable insights for optimizing milling processes.