Milling force model for asymmetric end-mills during high-feed milling on AISI-P20

Manufacturing molds for plastic parts injection are a particular machining domain, where challenging materials, like AISI P20 steel, forced to satisfy the highest surface quality requirements. Before mirror polishing, milling operation is common and task due drilling with same tool. Thus, special cutting tools, asymmetric indexable type, often used. This tool presents two geometrically equal positive inserts – one placed horizontally other vertically flexible of holes, cavities, floors, walls. Rough-medium operations lead complicated relationship between conditions geometrical parameters, making it balance life both inserts. The novelty this work propose model force prediction an explain separated behavior determine better compromise life. experimental tests were done validation then wear testing improved conditions. results predicted by proved that changing depth cut from 0.3 mm 0.8 mm, in was more balanced, increasing chip volume up 1.7 times.