日本機械学会 第24回設計工学部門講演会2014.9.17-19 Copyright (C) 2014 一般社団法人日本機械学会 [No.14-27] 日本機械学会 第24回設計工学部門講演会講演論文集〔2014.9.17-19, 徳島県徳島市 2308 Effect Cutting Parameters on Surface Roughness during End Milling of AISI D2 Tool Steel Mohd Amal ABD. HALIM* 1 Mohd Shahir KASIM 2 Mohd Amri SULAIMAN 3 Effendi MOHAMAD 4 Teruaki ITO 5 * 1,2,3,4 Faculty of Manufacturing Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100, Durian Tunggal, Melaka, Malaysia * 5 The University of Tokushima, Institute of Technology and Science Minami-Josanjima 2-1, Tokushima-shi, Tokushima, 770-8506 Japan This paper study the effect of three different numerical cutting parameters on surface roughness using during high speed machining. This experiment was carried out to investigate the effect machining parameters of AISI D2 tool steel using an insert end mill. The experiment work plan was carried out using Box-Behken techniques, a part of response surface methodology (RSM) approach. The effect of variable milling cutting parameters were studied to evaluate their effects on surface roughness. In this study, the cutting speed, feed rate, depth of cut and width of cut were in the range of 100-150 m/min, 0.1-0.2 mm/tooth, 0.2 mm and 2.0-8.0 mm respectively. The effect of input factors that on the responds were identified by using mean of ANOVA. The responds of surface roughness then simultaneously optimized. The validation of the test reveals the model accuracy 9%. Key Words: D2 tool steel, end milling, surface roughness, ANOVA. Box-Behnken, response surface methodology 1. Introduction Increasing product quality, delivery time and productivity of the machined parts are the main challenges of metal- based industry. There has been increased interest in machining condition in satisfying manufacturing requirement includes surface finish, one of important criteria in manufacturing engineering. The performance and quality of a product is directly associated to surface integrity achieved by final machining [ 1 ].The product quality included the surface roughness that which has a small tolerance, and lowest surface roughness, Ra. According to [ 2 ], due to its high productivity and throughput, high-speed machining (HSM) CNC milling technology has been increasingly used in the manufacture of mould and die. P.G Benardos et al., (2002) proposed an automated and flexible manufacturing system are employed for that purpose along with CNC machines that are capable of achieving high accuracy and with very low processing time. AISI D2 tool steel (JIS SKD11), a high chromium, high carbon, tool and die steel with hardness 54-62 HRc, exhibits remarkable characteristics and has consequently risen as the material with having high temperature operations, high strength, very high resistance to cracking and high resistance to softening and wear. Basically D2 tool steel is commonly used in mould and die making, cutting tool, aerospace, and power generation industries. The advantage of D2 steel because of excellent wear resistance and deep hardening characteristics. However, AISI D2 tool steel was generally known as the difficult material to be machined because of its high abrasion resistance, and high strength properties [ 3 ]. *1,2,3 Non-member，Universiti Teknikal Malaysia Melaka (Hang Tuah Jaya, 76100, Melaka, Malaysia) *4 Member，Universiti Teknikal Malaysia Melaka *5 Member，The University of Tokushima Japan E-mail: shahir@utem.edu.my