An investigation on machinability of AISI D2 steel during hard milling with multi-resolution analysis of vibration

Abstract

Vibration is a major concern in hard milling process as it adversely affects productivity, surface finish, tool wear, energy consumption, etc. The aim of this paper is to investigate the effects of cutting parameters on acceleration of vibration, acoustic pressure, surface finish, and tool flank wear in face milling of AISI D2 steel. Each cutting parameter was varied in four levels while keeping the maximum value of the other two parameters as constant. Wavelet transform was used to decompose the signals of vibration. Acceleration of vibration has been found to rise with increasing cutting speed in the range of 100 to 180 m min−1. In general, acoustic pressure was found to increase with increasing depth of cut and cutting speed. The results showed that increasing cutting speed leads to reduction in surface roughness while feed rate and cutting depth have opposite effects. It was revealed that while flank wear increases with increasing depth of cut and feed rate, it reduces when cutting speed is raised in the range of 100 to 180 m min−1.