A study of cutting forces and surface finish in high-speed machining of AISI H13 tool steel using carbide tools with TiAlN based coatings

High-speed machining (HSM) has emerged as a key technology in rapid tooling and manufacturing applications. In this study, the effect of increased spindle speeds on surface finish is examined. Physical vapour deposition (PVD) coated ball-nose micrograin carbide tools are used in finishing cuts for spindle speeds up to 42 000 r/min and a real-time force acquisition system is used to study the orthogonal forces. The importance of orthogonal force components to surface finish prediction and control is explored. The results show that Fz axial force has a very strong correlation with surface finish and that increased spindle speeds lead to far superior surface finish. Multilayer TiAlN coated carbides were found to generate the best surface finish while the uncoated tool and TiAlN + WC/C lubricant coating led to a severe degradation of surface finish at increased spindle speeds.