High-speed Cutting Process Parameters S50C Steel Mold Optimization

In recent years, as a typical representative of the advancedmanufacturing technology, high-speed machining technology has beenrapid development. High-speed machining is widely used in aviation,aerospace, automotive, mold and other fields because of its uniqueadvantages such as high precision, high efficiency and low pollution andso on. Die steel is a kind of indispensable material in mould manufacturingfield. However, die steel generally has the characteristics of highstrength and high hardness, therefore the temperature rising is larger andtool wear is more serious in the process of machining, resulting in thequality of the mould surface is difficult to control. As a result, theresearch on mould surface quality is a very important direction ofhigh-speed machining technology. In this paper, high-speed machining ofdie steel is investigated from two aspects of simulation and experiment,aiming at providing guidance for high-speed machining of mould.Simulation of high-speed machining is a new research field. Based onthe study of the mechanism of high-speed machining, high-speedmachining simulation model of die steel is established by the finiteelement software ABAQUS/Explicit. The formation process of chip issimulated. At the same time the distribution of stress, strain,temperature and the effect law of cutting speed on cutting force arestudied. Further study on high-speed machining of die steel is carriedout from the perspective of simulation.Surface roughness is an important index to measure the quality ofmold. Surface roughness affect directly wear resistance, corrosionresistance, and the service life of mould. The surface roughness isaffected by many factors. The effect of process parameters on surfaceroughness is the most significant. The proper selection of parameters isone of the effective ways to reduce the surface roughness and improvethe quality of mould. Toroidal cutter is applied in the high-speed millingexperiments of S50C die steel. The effect law of spindle speed, feed rate, axis depth, radial width and tool angle on the surface roughness isinvestigated through the single factor experimental method. Thesignificant degree of various parameters are analysed through theorthogonal experimental method. Surface roughness prediction model andparameter optimization model are established by methods of neuralnetwork and genetic algorithm combined with experimental result. Theoptimal process parameters of S50C die steel are calculated by models.In order to facilitate prediction, surface roughness prediction softwareis designed in MATLAB. Finally, executable file is generates to facilitatethe use of the prediction model.