Performance evaluation of end milling aluminium epoxy using HSS cutting tool

Abstract

The latest introduction of particulate-filled polymer composite materials for rapid tooling applications has led CNC machining to become a rather appealing alternative to additive rapid prototyping processes. Aluminum filled epoxy tooling technique plays a main role in rapid tooling applications. However, aluminum filled epoxy composites have its own disadvantages, namely low compressive strength, high wear rate and low hardness. This material is considered suitable for the high-speed CNC milling of injection molds and forming dies, nonetheless, its machinability characteristics have not been examined in detail in any other studies. Study on machining of aluminium particulate filled epoxy material is still lacking particularly in the investigation the performance of the high speed end milling using high speed steel cutting tool. Experiments were conducted to evaluate surface roughness, tool wear, and chip formation. The machining parameter of cutting speed was varied at three level whereas feed and depth of cut were kept constant. It was found that TiCN coated HSS tool outperformed uncoated HSS tool in terms of tool life and surface roughness when end milling aluminum particulate filled epoxy composite material at all cutting conditions. Cutting speed significantly affects the surface roughness of the machined surface whereby high cutting speed resulted in better surface finish. Lower cutting speed should be employed when end milling aluminum particulate filled epoxy composite material in order to achieve a longer tool life performance.