Numerical Investigation on Effect of Rounded Cutting-Edge Radius and Machining Parameters in End Milling of AISI H13 Tool Steel


  • Husni Nazra Abu Bakar
  • Jaharah A. Ghani
  • Che Hassan Che Haron





Chip morphology, Cutting-edge radius, Cutting force, Cutting temperature, Thirdwave AdvantEdge.


Rounded cutting-edge radius is commonly applied to finish and semi-finish cutting, precision machining and micro-machining. The optimum effect is closely related to the work and tool material as well as machining parameters. However, for numerous cutting process, the optimal radius of rounded cutting-edge radius and machining parameters applied in the AISI H13 of end-milling is yet unknown Therefore, in improving tool life and cutting tool performance, a suitable design of cutting edge geometry regarding cutting edge-radius and machining parameters need to be examined and properly selected. In this regard, the paper deals to examine the effect of cutting edge-radius in rounded form and machining parameters of cutting force, cutting temperature and chip formation through the end-milling process of AISI H13 using uncoated cemented carbide cutting tool through finite element simulation of Thirdwave AdvantEdge 7.2 software. The machining parameters applied in the simulation setup were 200 and 240m/min of cutting speed, 0.03 and 0.06mm/tooth of feed-rate and axial depth of cut of 0.1 and 0.2mm while width of cut in radial direction was kept constant at 6.0mm. The cutting geometries includes the cutting-edge radius of 0.03 and 0.05mm and 10° of rake angle. The obtained results revealed that cutting forces and cutting temperature is increase as depth of cut in axial direction and cutting-edge radius increases while increasing value of speed and feed-rate of cutting resulted in decreasing cutting forces but increasing cutting temperature. The maximum cutting temperature is 674.91℃. The value obtained is lesser than the AISI H13 austenitizing temperature, therefore a layer known as white layer is supposedly hard to be created based on the cutting geometry and machining parameters applied.  


[1] Wyen CF & Wegner K, "Influence of cutting edge radius on cutting forces in machining titanium", CIRP Annals-Manufacturing Technology, Vol.59, No.1, (2010), pp.93-96

[2] Denkena B, Kohler J & Ventura CEH, "Customized cutting edge preparation by means of grinding", Precision Engineering Vol.37, No.3, (2013), pp.590-598

[3] Yen YC, Jain A & Altan T, "A finite element analysis of orthogonal machining using different tool edge geometries", Journal of Material Processing Technology Vol.146, No.1, (2004), pp.72-81

[4] Rech J, "Influence of cutting edge preparation and surface issues", International Conference Smart Solutions for Metal Cutting, HSS Forum Aachen, (2005), pp.1-12

[5] Bassett E, Kohler J & Denkena B, "On the honed cutting edge and its side effect during orthogonal turning operation of AISI1045 with coated WC-Co inserts", CIRP Journal of Manufacturing Science and Technology, Vol.5, No.2, (2012), pp.108-126

[6] Kandrac L, Mankova I & Vrabel M, "Cutting edge preparation in machining process", Zeszyty Naukowe Politechniki Rzeszowskiej, Mechanics, Vol.85, No.2, (2013), pp.149-159

[7] Wang CY, Tian JJ, An QL & Chen M, "Numerical investigation on effect of rounded cutting edge radius in milling of ultra-high-strength steel 30Cr3SiNiMoVA", Advanced Materials Research, Vol.797, (2013), pp.202-207

[8] Afazov S, Ratchev S & Segal J, "Effect of the cutting tool edge radius on the stability lobes in micro milling", Advanced Materials Research, Vol.223, (2011), pp.859-868

[9] M'Saoubi R & Chandrasekaran H, "Investigation of the effect of tool micro-geometry and coating on tool temperature during orthogonal turning of quenched and tempered steel", International Journal of Machine Tools and Manufacture, Vol.44, No.2-3, (2004), pp.213-224

[10] Quteiro JC, Dias AM & Jawahir IS, "On the effects of residual stresses induced by coated and uncoated cutting tools with finite edge radii in turning operations", CIRP Annals, Vol.55, No.1, (2006), pp.111-116

[11] Zhang Q, Zhang S & Li J, "Three dimensional finite element simulation of cutting forces and cutting temperature in hard milling of AISI H13 steel", Procedia Manufacturing, Vol.10, (2017), pp.37-47

[12] Riza M & Adesta EYT, "Investigation of cutting temperature for AISI H13 in high speed end milling", International Journal of Engineering Materials and Manufacture, Vol. 1, No.1, (2016), pp.27-34

[13] Sato M, Tamura N & Tanaka H, " Temperature variation in the cutting tool in end milling", Journal of Manufacturing Science and Engineering, Vol.133, No.2, (2011), pp.1-7

[14] Coz GL & Dudzinski D, "Temperature variation in the workpiece and in the cutting tool when dry milling Inconel 718", The International Journal of Advanced Manufacturing Technology, Vol.74, No.5-8, (2014), pp.1133-1139

[15] Wang F, Tao Q, Xiao L, Hu J & Xu L, "Simulation and analysis of serrated chip formation in cutting process of hardened steel considering ploughing-effect", Journal of Mechanical Science and Technology, Vol.32, No.5, (2018), pp.2029-2037

[16] Cui X, Zhao J & Tian X, "Cutting forces, chip formation, and tool wear in high-speed face milling of AISI H13 steel with CBN tools", The International Journal Advance Manufacturing Technology, Vol.64, No. 9-12, (2013), pp.1737-1749

[17] Outeiro J, "Optimization of machining parameters for improved surface integrity of AISI H13 tool steel", Machines et Usinage a Grande Vitesse (MUGV) France, (2012), pp.1-10

[18] Li B, Zhang S, Yan Z & Zhang J, "Effect of edge hone radius on chip formation and its microstructural characterization in hard milling of AISI H13 steel", The International Journal of Advanced Manufacturing Technology, (2018), pp.1-14

[19] Afazov SM, Ratchev SM & Segal J, "Prediction and experimental validation of micro-milling cutting forces of AISI H13 steel at hardness between 35 and 60 HRC", The International Journal Advance Manufacturing Technology, Vol.62, No.9-12, (2012), pp.887-899

[20] Zhang S & Guo YB, "An experimental and analytical analysis on chip morphology, phase transformation, oxidation, and their relationships in finish hard milling", International Journal of Machine Tools and Manufacture, Vol.49, No.11, (2009), pp.805-813

[21] Park SH, Robust Design and Analysis for Quality Engineering, Chapman & Hall, London, UK (1996), pp:68-69.

[22] Hou J, Zhou W, Duan H, Yang G, Xu H & Zhao N, "Influence of cutting speed on cutting force, flank temperature, and tool wear in end milling of Ti-6Al-4V alloy", The International Journal Advance Manufacturing Technology, Vol.70, No.9-12, (2014), pp.1835-1845

[23] Bogdan BM, Sabin PM, Stefan S & Dan P, "Unconventional technologies in preparation of microgeometry edges on cutting tools", Romanian Association of Nonconventional Technologies, (2013), pp.10-16

[24] Bouzakis KD, Michailidis N, Skordaris G, Kombogiannis S, Ha ijiyiannis S, Efstathiou K, Erkens G, Rambadt S & Wirth I, "Effect of the cutting edge radius and its manufacturing procedure, on the milling performance of PVD coated cemented carbide inserts", CIRP Annals, Vol.51, No.1, (2002) pp.61-64

[25] Trent EM & Wright PK, Metal Cutting, Butteworth-Heinemann, Woburn, MA, (2000), pp:23.

[26] Vyas A & Shaw MC, "Mechanics of saw-tooth chip formation in metal cutting", Journal of Manufacturing Science & Engineering, Vol.121, No.2, (2008), pp.163-172

View Full Article: