Superior surface integrity by sustainable dry hard milling and impact on fatigue

Dry milling is a sustainable finishing process in mold/die manufacturing. However, the progression of tool wear causes great concern on inferior surface integrity and reduced part life. This study focuses on the relationships among process conditions, surface integrity, and fatigue in dry milling of hardened H13 steel. Superior surface integrity including good surface finish, highly compressive residual stress, free-of white layer, and work-hardening can be produced up to flank wear at least 0.2 mm. Furthermore, fatigue life of the machined surfaces in finish conditions reaches over 1 million cycles under the synergistic effect of high compressive residual stress and work-hardening.