Vol.:(0123456789) 1 3 Journal of the Brazilian Society of Mechanical Sciences and Engineering (2018) 40:478 https://doi.org/10.1007/s40430-018-1400-5 TECHNICAL PAPER Performance of wiper geometry carbide tools in face milling of AISI 1045 steel J. V. R. Toledo 1  · E. M. Arruda 1  · S. S. C. Júnior 1  · A. E. Diniz 2  · J. R. Ferreira 1 Received: 3 April 2018 / Accepted: 6 September 2018 © The Brazilian Society of Mechanical Sciences and Engineering 2018 Abstract In recent years, the increase in technological advances in the metalworking industry enabled the development of new tools and machining processes, which guarantee high quality of the machined part and long tool life. Among the machining processes, milling has been extensively used in the fnishing of the automotive industry components. It is known that the surface of the machined workpiece obtained using milling display many irregularities caused by grooves or marks left by the tool during the cutting process. In this context, wiper geometry inserts are very useful for reducing surface roughness. Therefore, this work analyzed the infuence of the relationship between the length of the parallel land of the secondary cutting edge and the feed per tooth (b s /f z ) on the surface roughness of the AISI 1045 steel in face milling process. During the tests, standard geometry inserts were used together with wiper geometry inserts on a milling cutter, in order to reduce the surface roughness and to increase the material removal rate. Furthermore, the vibration signal was monitored. In the cutter assembly with only standard geometry inserts, the minimum workpiece average roughness Ra was obtained with a feed per tooth of 0.30 mm, while the assemblies with one and two wiper inserts presented the minimum roughness with feed per tooth of 0.83 mm. The main conclusion of this work was that the use of cutter assembly with 1 wiper geometry insert achieves a low roughness, a large material removal rate and a long tool life in the milling process. Keywords Face milling · Wiper geometry · Surface fnish · Tool life · Vibration 1 Introduction Scientifc investigations related to machining processes are extremely important for technological advancement in mechanical manufacturing. As it is an industrial production process, major investments are needed and the cost reduction plays an important role. In this context, due to the versatil- ity and capability to produce various surfaces, the milling process stands as one of the most used in the metalworking industry [1, 2]. Aspects such as high material removal rate, variety of tool geometries, high precision, speed of execution combined with a low cost, allow the milling process to be used in the manufacture of many kinds of geometries, open- ing possibilities for obtaining high-quality products [3]. The demand for high quality and fully automated produc- tion focuses attention on the surface condition of the prod- uct, especially the machined surface roughness, because it afects the product appearance, function, performance and reliability [4, 5]. Surface roughness is one of the most specifed customer requirements and the major indicator of surface quality on machined parts. The surface roughness is mainly a result of various controllable or uncontrollable process parameters. Surface roughness is an important measure of the quality of a product and also greatly infuences the production cost [2]. Moreover, surface quality is one of the most important aspects of milling operations, since these operations are fre- quently used in the last stages of the production cycle. To improve the surface fnish and the dimensional and geomet- ric properties of the part, it is important to verify the infu- ence of the diferent factors involved in the cutting process, Technical Editor: Márcio Bacci da Silva, Ph.D. * J. V. R. Toledo verissimo@unifei.edu.br 1 Universidade Federal de Itajubá, BPS Avenue, 1303, Itajubá, Minas Gerais 37500-903, Brazil 2 Universidade Estadual de Campinas, Mendeleyev st, 200, Cidade Universitária “Zeferino Vaz”, Campinas, São Paulo 13098-360, Brazil