article · Frontiers in Materials
Milling high-strength EN 24 steel presents challenges in achieving fine surface quality. This medium-carbon nickel-chromium-molybdenum alloy is widely selected for heavy-duty applications because of its resilience against damage, particularly under low-temperature conditions. Using coated tungsten carbide tool inserts, the machining process was evaluated across four primary variables: cutting speed, feed rate, depth of cut, and cutting fluid delivery. Response surface methodology combined with analysis of variance established predictive mathematical models to minimise surface irregularities. Optimal cutting conditions were achieved at a cutting speed of approximately 149.5 metres per minute, a feed rate of 340.3 millimetres per minute, a depth of cut of 0.6 millimetres, and a fluid flow rate of 12.5 litres per minute. These parameters delivered a low surface roughness measurement of 0.301 micrometres. Microstructural and profilometric evaluations confirmed significant improvements in surface integrity.
EN 24 steel is critical for heavy-duty engineering components that must withstand harsh and low-temperature environments. Enhancing the surface finish of machined parts reduces friction, wear, and structural defects. Identifying precise machining parameters lowers manufacturing defects, improves component durability, and reduces operational waste during fabrication without requiring costly trial-and-error procedures on the factory floor.
The findings offer applied and tested operating parameters directly relevant to heavy manufacturing, tooling workshops, and precision engineering firms machining high-strength steel alloys. By establishing exact operational settings for tungsten carbide tooling, machine operators can readily adopt these benchmarks to improve component quality and reduce process planning time. The research represents applied laboratory testing that is closely aligned with direct implementation in industrial computer numerical control milling operations.
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Introduction: Among alloys of medium-carbon and high-strength steel, EN 24 steel is characterised by its nickel-chromium-molybdenum composition. EN 24 steel is highly suitable for application in heavy-duty projects due to its notable resilience to damage, especially when exposed to low temperatures. With the objective of minimising surface irregularities, this research endeavours to enhance the milling process of EN 24 steel by employing coated tungsten carbide (WC) tool inserts. Methods: Feed rate, cutting speed, depth of cut, and cutting fluid are all crucial process factors in the experimental investigation. Four distinct levels are applied to each factor. The research utilises the Design of Experiments (DOE)-based Central Composite Design of Response Surface Methodology. To predict output parameters, mathematical models are developed utilising analysis of variance (ANOVA) for optimisation purposes. Results and discussions: Through the utilisation of multi-objective optimisation, the optimal combination for tungsten carbide inserts was determined, which provided surface irregularities of 0.301 µm. Cutting speed (CS) of 149.507 m/min, feed rate (FR) of 340.27 mm/min, depth of cut (DOC) of 0.599 mm, and cutting fluid (CF) of 12.50 L/min are the optimal parameters. The surface morphologies of the machined workpiece at particular parameter values can be discerned through scanning electron microscope (SEM) analysis, yielding significant insights. The optimal parameters that have been identified provide practical recommendations for improving the milling method of EN 24 steel when tungsten carbide inserts are utilised. Understanding the milling process in its entirety is facilitated by SEM analysis of surface morphologies and microstructures under particular cutting conditions. The morphology and surface irregularities of the machined workpiece are evaluated using profilometry, which provides additional insight into surface integrity. The discourse investigates the potential applications and implications of the results, as well as suggests directions for further study concerning the enhancement of milling processes for similar steel alloys.
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DOI: 10.3389/fmats.2024.1269608
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