Coated tools’ wear description in down and up milling based on the cutting edge entry impact duration

Milling operations are associated with significant tool impact loads. In the present investigations, coated carbide inserts were employed in down and up milling hardened steel, at appropriate cutting conditions and tool diameters, for attaining various cutting edge entry impact durations (CEEID). The unexpected tool life improvement in up milling, when inserts with rake chamfer instead of sharper round ones were applied, was explained via FEM-determined tool loads and their duration during the material removal. The effect of CEEID on the film failure was quantified by impact tests at various force data. The tool life was effectively described dependent on CEEID.