Original Article

Tool wear in high-speed face milling of

AISI H13 steel

Proc IMechE Part B:

J Engineering Manufacture
226(10) 16841693
IMechE 2012
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DOI: 10.1177/0954405412455378
pib.sagepub.com

Xiaobin Cui, Jun Zhao and Xianhua Tian

Abstract
In the present study, high-speed and ultra-high-speed face milling of AISI H13 steel (4647 HRC) is conducted in order
to acquire a thorough understanding of the tool wear evolution process and tool wear mechanisms in high-speed hard
milling. According to the variation trend of the tool life with cutting speed, three cutting speed ranges are identified. For
different cutting speed ranges, the tool wear evolution process and typical tool wear mechanisms are analyzed and compared. It is found that the cutting speed of 1400 m/min can be considered as a critical value for both the average value of
the resultant cutting force and tool life. The analysis of the tool wear mechanisms show that, as the number of cutting
speed range increases, on the tool flank face, oxidation wear influences more greatly, while the effect of adhesive wear
decreases. In the speed range 1400 m/min \ v 4 2400 m/min, the abrupt flaking that occurred on the tool rake face
was mainly caused by the increase of tool temperature, mechanical impact and thermal impact.

Keywords
Tool wear, high-speed, face milling, AISI H13 steel

Date received: 18 December 2011; accepted: 28 June 2012

Introduction
The concept of high-speed cutting (HSC) was first proposed by Salomon1 by means of high-speed milling
tests. Better surface quality and higher machining efficiency are expected to be obtained using HSC technology. There have been many valuable researches on
surface quality, tool wear characteristics, optimization
of cutting condition and finite element modeling in the
field of high-speed milling.28
High-speed milling has been extensively used in the
manufacturing of aluminum aeronautical and automotive components so as to efficiently generate smooth
surfaces with high geometric accuracy. With the development of cutting tools and machine tools, HSC technology has been used to manufacture the mold and dies
in their hardened state. Hard milling can even be an
alternative for the grinding process in some cases.9 It
has advantages, such as reduction of machining costs
and elimination of part distortion caused by heat treatment, etc.
At high cutting speeds, the mechanical properties of
the cutting tool are weakened by the high cutting temperature. The tool wear increases dramatically, leading
to the short tool life and impaired surface integrity. It
is of great importance to assess the tool wear evolution
process and tool wear mechanisms in high-speed face

milling of hardened steel. Valuable information can be

provided for enhancing the machining efficiency and
surface quality by means of tool wear assessment.
Deeper understanding of the tool wear will also be
valuable for the reasearchers who endeavor to manufacture tools for high-speed hard milling.
AISI H13 tool steel has great high-temperature
strength and wear resistence. It has been widely applied
in extrusion, extrusion mandrels, hot forging and pressure die casting. In this work, a block of AISI H13
steel, hardened to 46 to 47 HRC, was used. The influences of cutting speed on tool wear in high- and ultrahigh-speed face milling are focused on. For the purpose
of having a comprehensive understanding of the
effects of cutting speed, cutting speeds ranging from
200 m/min to 2400 m/min are adopted. The variations
of tool life and the tool wear evolution process with cutting speed are investigated. The typical wear

Key Laboratory of High Efficiency and Clean Mechanical Manufacture of

Ministry of Education, Shandong University, China
Corresponding author:
Jun Zhao, Key Laboratory of High Efficiency and Clean Mechanical
Manufacture of MOE, School of Mechanical Engineering, Shandong
University, Jinan 250061, China.
Email: zhaojun@sdu.edu.cn

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mechanisms are analyzed and compared for tools tested
within different cutting speed ranges.

Literature review
Previous studies on high-speed milling of hardened steels
have concentrated mainly on end milling and side milling
operations. Some of these previous researches focused
on the investigation of surface roughness in end and side
milling. Ghani et al.10 stated that when high cutting
speed, low feed rate and low depth of cut were adopted,
good surface finish can be obtained in semifinish and finish machining of hardened AISI H13 steel. Vivancos et
al.11 presented a mathematical model for the surface
roughness in high-speed ball-end milling of hardened
steels using design of experiments. Vivancos et al.12 conducted a study of the surface roughness obtained in
high-speed side milling of hardened die steels. The influences of cutting parameters were studied by means of a
2421 fractional factorial design of experiments.
Many other studies have concentrated on tool performance and tool wear mechanisms in end milling.
High-speed milling of hardened steels was conducted
by Fallbohmer et al.13 to determine the performance of
advanced cutters and identify recommended cutting
speeds and feed rates. Machining time and surface finish focused on the investigation. Toh14 investigated and
evaluated different cutter path orientations in highspeed finish milling of hardened steel. It was found that
employing a vertical downward orientation achieved
the longest tool life. But vertical upward orientation
was generally preferred in terms of workpiece surface
roughness. Aslan15 studied the performance and wear
behavior of different cutting tools in end milling of
X210 Cr12 cold-work tool steel (62 HRC). The results
showed that cubic boron nitride (CBN) tools exhibited
the best cutting performance in terms of both flank
wear and surface finish. End milling of AISI D2 tool
steel (58 HRC) was conducted by Koshy et al.16
Analysis of flank wear indicated that chipping, adhesion and attrition were the governing mechanisms
responsible for tool wear. The workpiece surface
roughness was in the range 16 mm Ra for carbide
ball-nose end mills. Ghani et al.17 investigated the wear
mechanism of TiN-coated carbide and uncoated cermets tools at various combinations of cutting parameters in end milling of hardened AISI H13 tool steel.
Urbanski et al.18 studied the tool wear, workpiece surface roughness and cutting force in high-speed ball-end
milling of hardened AISI H13 hot work steel.
Relatively few researches have been conducted in
the field of face milling of hardened steels. Ultra-highspeed face milling experiments for cast iron, AISI 1045
tempered carbon steel and AISI 1045 hardened carbon
steel were performed by Liu et al.19 using different cutting tools, such as polycrystalline cubic boron nitride
(PCBN), ceramic, coated carbide and fine-grained
carbide. The tool wear types vary with different

combinations of workpiece and tool material. It is

found that the wear patterns were rake face wear, flank
wear, chipping and breakage. The wear mechanisms
were mechanical friction, adhesion, diffusion and
chemical wear, promoted by cutting forces and high
cutting temperature. Siller et al.20 studied the impact of
a special carbide tool design on the process viability in
face milling of hardened AISI D3 steel (60 HRC), in
terms of surface quality and tool life. Results showed
that surface roughness Ra ranging from 0.1 to 0.3 mm
can be obtained with an acceptable level of tool life.
It can be concluded that there are many studies1018
conducted in the field of high-speed end and side
milling of hardened steel. These previous researches
provided much valuable information about surface
integrity, tool performance and tool wear mechanisms.
However, scant researches19,20 were conducted for
high-speed face milling of hardened steel. In the present
study, high-speed face milling of AISI H13 steel (46 to
47 HRC) is conducted to investigate the tool wear evolution process and tool wear mechanisms.
Both cutting forces and tool temperature influence
tool wear mechanisms substantially. However, quantitative analysis was not conducted for either of them in
the previous researches on tool wear in high-speed face
milling of hardened steel. This article presents quantitative analysis of cutting forces and tool temperature in
order to enhance the current understanding of the
effects of mechanical and thermal loads on tool wear in
high-speed face milling of hardened steel.
For the purpose of maintaining competitiveness,
increasingly high cutting speed is adopted by industries
to machine hardened steel. In the previous studies,
high-speed face milling experiments with cutting speeds
above 1100 m/min were not performed to investigate
the tool wear mechanisms. The highest cutting speed
(2400 m/min) adopted in this work is much higher than
those in the previous researches. The present study
increases the current understanding of tool wear
mechanisms at higher cutting speed in high-speed face
milling of hardened steel.

Details of experiment and finite element

simulation
Experimental procedures
The nominal chemical composition of AISI H13 tool
steel is listed in Table 1. The width and length of the
block are 75 mm and 100 mm, respectively.
Tungsten carbide inserts SEEX 09T3AFTN-D09
coated with Ti(C, N)Al2O3 were used. A Seco
R220.53-0125-09-8C tool holder, with a tool diameter
of 125 mm, axial rake angle of 20, radial rake angle of
5 and major cutting edge angle of 45, was applied.
Only one of the teeth was used in all the tests so as to
avoid the effect of small differences between the teeth
and maintain a constant cutting condition. The experiments were performed on a vertical computer

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Table 1. The chemical composition of AISI H13 tool steel (wt.%).

Mn

Cr

Si

Mo

Ni

Fe

0.200.50

0.320.45

4.755.50

0.801.20

0.801.20

1.101.75

00.30

Bal.

numerically controlled (CNC) machining center

DAEWOO ACE-V500 with a maximum spindle rotational speed of 10,000 r/min and a 15-kW drive motor.
All the tests were carried out in a dry condition.
Symmetric milling was applied. The radial depth of
cut ae was fixed as 75 mm. Milling tests with cutting
speed v ranging from 200 to 2400 m/min at an interval
of 200 m/min were performed. The axial depth of cut
ap and feed rate fz were set to be 0.2 mm and 0.04 mm/
tooth, respectively.
Each trial was replicated three times. The cutting
forces were measured during the first pass of the workpiece surface by means of a Kistler piezoelectric dynamometer (type 9257B) mounted on the machine table as
shown in Figure 1. The charge generated at the dynamometer was amplified by a multi-channel charge amplifier (type 5070A). The sampling frequency of data was
set to be 7000 Hz. The value of tool flank wear was
examined periodically with an optical microscope during the milling process. The tool flank wear was measured three times for each insert and the average value
was calculated. Tool life was recorded when the flank
wear reached or increased over 0.3 mm. The worn tools
were observed using scanning electron microscopy
(SEM) (JSM-6510LV, Japan) and energy-dispersive
X-ray spectroscopy (EDS).

Finite element simulation of face milling

Since there are great difficulties in measuring the cutting temperature in the milling process, finite element
simulation of face milling was conducted to investigate

Figure 1. The experimental set-up for face milling test.

the evolution of tool temperature. The simulation process was set to be consistent with the actual milling
condition.
Lagrangian formulation embedded in the package
(Deform 3D) was applied in the modeling of the face
milling. Geometries of the workpiece and the single
insert cutter are shown in Figure 2. Tetrahedron elements were employed in the meshing of the cutter and
the workpiece. Re-meshing technology and local
refining technology were used in the workpiece meshing. The boundary conditions were specified to constrain the top surfaces of the tool in vertical
directions. The tool rotated at the specified cutting
speeds. The workpiece was constrained in vertical and
lateral directions on the bottom surface. The initial
temperature of the workpiece and cutter was set to be
20 C. The tool was modeled as a rigid but heat transfer body.
Adopting a suitable material-constitutive model for
the workpiece is essential for successfully simulating
the metal cutting process. The JohnsonCook model
has been used by many researchers to investigate high
strain rate and high temperature deformation behavior
of steels. The JohnsonCook constitutive equation was
used as
"

! #

 
e
Ta Tr m
n
s = A + Be 1 + C ln

1
Tm Tr
e
0

1

where s, e, e and Ta are the shear stress, shear strain,

shear strain rate and absolute temperature, respectively.
The material characteristics are determined by parameters, such as the strain hardening exponent n, the
strain rate sensitivity C, the thermal softening coefficient m, the yield strength A, the hardening modulus B,

Figure 2. Geometries of the workpiece and the cutter.

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Cui et al.

The evolutions of Fra, Frim, Tha and Thim with cutting

speed are shown in Figure 3. The dotted lines in Figure
3 show the development of Fra and Frim obtained by
means of finite element simulation. It can be found that
they are close to the experimental results. This validates
the simulation of face milling.
Figure 3 shows that Fra initially increases with
increasing cutting speed. When the cutting speed is
about 1000 m/min, it begins to decrease. As the cutting
speed increases over 1400 m/min, it increases with
increasing cutting speed. Frim, Tha and Thim all increase
when the cutting speed increases. The increasing trends
of them indicate that, when the cutting speed increases,
the tool temperature becomes higher and both the
mechanical and thermal impact become more severe.

Tool-life and tool-wear evolution

Figure 3. The evolutions of Fra, Frim, Tha and Thim with cutting
speed v: (a) the evolutions of Fra and Tha with cutting speed v; (b)
the evolutions of Frim and Thim with cutting speed v.

the reference plastic strain e0 , the reference temperature

Tr and the melting temperature Tm. The Johnson
Cook parameters for AISI H13 tool steel are adopted
from Chen et al.21 as A = 715 MPa, B = 329 MPa,
C = 0.03, n = 0.28 and m = 1.5. The thermal conductivity and specific heat capacity of the workpiece
are 28.4 W/(mK) and 560 J/(kgK), respectively. The
thermal expansion coefficient is 10.4 3 106/K.

Results and discussion

Cutting force and tool temperature
During the first pass of the workpiece surface, the cutting force signal was recorded when the cutter reached
the midpoint of the workpiece. For each test, three cutting periods were picked. The average value and maximum value of the resultant cutting force were
calculated and represented by Fra and Frm, respectively.
In order to describe the mechanical impact, Frim is calculated as Frim = Frm Fra.
In the cutting period, the development of the highest
tool temperature Th is obtained by means of finite
element simulation of the face milling. Tha and Thm
are used to represent the average value and
maximum value of Th, respectively. For the purpose of
reflecting the thermal impact, Thim is calculated as
Thim = Thm Tha.

In the present study, the tool life L is represented by the

volume of the removed metal (mm3). Figure 4 shows
the development of the average value of tool life L and
tool wear with cutting speed.
The assessment of the measurement uncertainty was
conducted based on the method introduced in literature.22 The value of the tool flank wear was examined
using an optical microscope with a magnification of
3200. The selected magnification, repeated placement
of the cutting tool, the divisions on the optical microscope and the calibration uncertainty will lead to possible errors of the measurement. It is assumed that the
measurement errors are independent of each other and
the combined standard uncertainty is normally distributed. The expanded uncertainty is obtained as 0.012 mm
by means of multiplying the combined standard uncertainty by a coverage factor of 2, giving a confidence of
approximately 95%. The evolutions of tool flank wear
shown in Figure 4 are used to compare the developing
trends of tool wear at different cutting speeds. Since the
flank wear at lower levels of removed metal is comparable with measurement uncertainty, the relatively lower
values of flank wear should not be considered. The
plotted curves of tool flank wear should also provide
sufficient information for the analysis of tool wear
developing trends. Taking the above discussions into
consideration, flank wear below 0.06 mm is not considered in Figure 4. The measurement uncertainty
(0.012 mm) accounts for about 20% of 0.06 mm.
It can be seen from Figure 4 that the curve of tool
life can be divided into three regions. When the cutting
speed is between 200 and 1000 m/min the tool life
decreases with increasing cutting speed. As the cutting
speed surpasses 1000 m/min, the tool life begins to
increase until 1400 m/min. In the speed range of 1400
to 2400 m/min, increasing cutting speed leads to shorter
tool life.
The increasing trend of the tool life can be mainly
attributed to the decreasing trend of the average value
of resultant cutting force, as shown in Figure 3. It seems
that the cutting speed of 1400 m/min is a critical value

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Figure 4. The evolutions of tool life and tool wear with cutting speed v (fz = 0.04 mm/tooth, ap = 0.20 mm): (a) the evolution of
tool life L with cutting speed v; (b) the evolution of tool wear in cutting speed range 1 (200 4 v \ 1000 m/min) ; (c) the evolution
of tool wear in cutting speed range 2 (1000 4 v 4 1400 m/min) ; and (d) the evolution of tool wear in cutting speed range 3
(1400 \ v 4 2400 m/min).

for both the mechanical load and tool life. At this critical cutting speed, a relatively low value of the average
resultant cutting force and a relatively long tool life can
be obtained at the same time.
In different speed ranges, namely 200 m/min 4 v
\ 1000 m/min (speed range 1), 1000 m/min 4 v 4
1400 m/min (speed range 2) and 1400 m/min \ v 4
2400 m/min (speed range 3), the characteristics of the
tool wear evolution process differs greatly, as shown in
Figure 4.
It can be seen from Figure 4 that, in speed ranges 2
and 3, the tool wear increases rapidly at the end of tool
life, which is different from those of the tools tested in
speed range 1. In speed range 1, the wear rate changes
little in the whole tool life, though it becomes a little
higher when approaching the end of tool life. While in
speed range 2, when the tool flank wear is more than
0.2 mm, tool wear increases rapidly. As for speed
range 3, the wear rate is relatively small when the tool
wear value is below 0.1 mm. However, when 0.1 mm
is surpassed, the tool wear rate becomes much higher,
and the tools are worn out with a high value of tool
wear.

It can be seen from Figure 3 that, although the average value of resultant cutting force has a decreasing
trend in speed range 2, these values are still high.
Moreover, the higher cutting speed leads to higher
tool temperature, and more severe mechanical and
thermal impact. When the tools are tested in speed
range 3, the loading condition is more fierce than that
in range 2, as shown in Figure 3. Under such severe
loading conditions, as for flank wear, a vicious circle
will probably be obvious at the end of tool life: the
more severe tool wear leads to higher cutting force,
higher tool temperature, and more severe mechanical
impact and thermal impacts, all of which subsequently lead to higher tool wear rate. At the end of
tool life, the flank wear value is relatively high and
the effects of this vicious circle are greater, explaining
the rapid increase of tool wear.

Tool wear mechanisms

Figures 57 show the typical morphologies of the worn
tools tested within the three cutting- speed ranges,
respectively.

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Cui et al.

Figure 5. SEM images of the typical worn tool tested in speed range 1 (v = 400 m/min, fz = 0.04 mm/tooth, ap = 0.20 mm).

The wear patterns of the tools tested within speed

range 1 are depth of cut notch wear and flank wear, as
shown in Figure 5(a). There is no obvious wear on the
rake face. Figure 5 shows that the wear mechanisms of
the tool are abrasive wear and adhesive wear, which
appear on the flank face of the tool.
For the tools tested in the three cutting speed ranges,
the EDS analyses of the regions, similar to where points
1 and 2 are located on the tool flank face in Figure 5(a),
are conducted. As for the tools tested in the other two
cutting speed ranges (speed ranges 2 and 3), the points
located in these regions are also denoted as points 1
and 2, correspondingly as shown in Figures 6(d) and
7(b). It is found that the wear mechanisms of these
regions are similar except for the changes of the element content. The evolutions of elements Fe and O in
similar regions with cutting speed range number are
shown in Figure 8, where region a represents the
region where point 1 is located and region b represents
the corresponding region for point 2. The contents of
the elements (Fe, Cr, V, etc.) from the workpiece
change in a similar way with the cutting speed range
number. Therefore, element Fe is chosen to investigate the elements from the workpiece. Since each test
was replicated three times, EDS analyses of the other
tested cutting tools were also conducted. The results

show similar trends to that shown in Figure 8, in spite

of some value changes.
The EDS analysis of region b reveals elements, such
as Fe, Cr, V, etc., from the workpiece and element O.
While the EDS analysis of region a shows a lower content of the elements from the workpiece but higher content of element O. In region a, oxidation wear is more
serious than that in region b. The higher content of the
workpiece in region b indicates that more severe adhesion occurred in that region. It is inferred that the more
severe adhesion caused the lateral crack shown in
Figures 5(c), 6(d) and 7(b). It can be seen from Figure
8 that, for these regions, as the number of the cutting
speed range increases, oxidation wear is influenced
more greatly, while the effect of adhesive wear
decreases.
Figure 6 shows that the wear mechanisms of the
tools tested within speed range 2 are coating delamination, microchipping of the cutting edge, adhesive wear
and abrasive wear. As shown in Figure 6(a), obvious
coating delamination occurs on the rake face of the cutting tool, which is not encountered in speed range 1.
This can be attributed to the more severe thermal and
mechanical impact, as shown in Figure 3. The more
severe impact could also be the reason why microchippings appear.

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Figure 6. SEM images of the typical worn tool tested in speed range 2 (v = 1000 m/min, fz = 0.04 mm/tooth, ap = 0.20 mm).

The EDS analysis of points 3 and 4, denoted in

Figure 6(b), shows that it is the chip that adheres to the
cutting edge. The content of element O at points 3 and
4 are 6.14 wt.% and 9.92 wt.%, respectively. The relatively high content of element O indicates that the high
cutting temperature induced by high cutting speed
accelerated the chemical reaction between the chip and
oxygen.
Figure 7 shows the SEM images of the worn tool
tested in cutting speed range 3. As for flank wear, the
wear mechanisms are similar to that of the tools tested
within speed range 2. Adhesive wear, abrasive wear

and oxidation wear seem to be the wear mechanisms.

However, for the wear mechanisms of the rake face,
there are great differences between speed range 2 and 3.
In speed range 3, a large flaked region and more severe
chippings appear on the rake face and cutting edge,
respectively. The average values of the resultant cutting
forces measured within speed range 3 are similar to
those measured within speed range 2, as shown in
Figure 3. Therefore, the flaked region and more severe
chippings are mainly caused by the increase of tool
temperature, mechanical impact and thermal impact in
speed range 3.

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Cui et al.

Figure 7. SEM images of the typical worn tool tested in speed range 3 (v = 2200 m/min, fz = 0.04 mm/tooth, ap = 0.20 mm).

Figure 7(c), (d) and (e) shows that liquid-like and

sphere-like materials are distributed on the rake face. It
can be seen from Figure 7(c) that there are many gas
cavities in the region where point 3 is located. The content of oxygen at points 3 and 4 is very large
(42.51 wt.% and 20.99 wt.%, respectively). It is inferred
that they are the chips that have melted owing to the
high cutting temperature. Fierce reaction between the
chip and oxygen happened. Taking the melting point of

H13 tool steel into consideration, the highest cutting

temperature should be more than 1427 C.

Conclusions
Experiments and finite element simulations were
conducted in this article so as to acquire a thorough
understanding of tool wear mechanisms in high- and
ultra-high-speed face milling of hardened steel, and

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higher cutting speed, coating delamination and
microchipping happened on the rake face and cutting edge, respectively. As for speed range 3, the
wear mechanisms of the flank face were similar to
those of tools tested within speed ranges 1 and 2.
The abrupt flaking, which occurred on the rake
face, was caused by the increase of tool temperature, mechanical impact and thermal impact in
speed range 3. When the number of the cutting
speed range increased on the tool flank face, oxidation wear influenced more greatly, while the effect
of adhesive wear decreased.
Funding
This work is supported by the National Basic Research
Program of China [2009CB724402]; the National
Natural Science Foundation of China [51175310] and
the Graduate Independent Innovation Foundation of
Shandong University (GIIFSDU) [yzc10119].
References

Figure 8. The content of elements. (a) The content of element

Fe in regions a and b versus cutting speed range; (b) the content
of element O in regions a and b versus cutting speed range.

provide valuable information for the application of

high-speed hard milling. The following conclusions can
be drawn from the results of this work.
1.

2.

3.

By means of identifying the developing trend of

the tool life, the cutting speed was divided into
three ranges, namely, 200 m/min 4 v \ 1000 m/
min (speed range 1), 1000 m/min 4 v 4 1400 m/
min (speed range 2) and 1400 m/min \ v 4
2400 m/min (speed range 3). At the critical cutting
speed of 1400 m/min, both a relatively low average
resultant cutting force and a relatively long tool
life can be obtained.
In cutting speed ranges 2 and 3, at the end of tool
life, a vicious circle was obvious. The more severe
tool wear led to higher value of cutting force, tool
temperature, mechanical impact and thermal
impact, all of which subsequently led to the higher
tool wear rate. This explained the rapid increase of
tool wear at the end of tool life.
The wear mechanisms of the tool tested in speed
range 1 were abrasive wear, adhesive wear and oxidation wear, which occurred on the flank face of
the tool. In speed range 2, owing to the more severe
mechanical and thermal impact resulting from the

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Appendix
Notation

yield strength
radial depth of cut
axial depth of
hardening modulus
strain rate sensitivity
average value of the resultant cutting
force
difference between the maximum and the
average resultant cutting force
maximum value of the resultant cutting
force
feed rate
tool life
thermal softening coefficient
strain hardening exponent
absolute temperature
highest tool temperature
average value of the highest tool
temperature
difference between the average value and
maximum value of the highest tool
temperature
melting temperature
reference temperature
maximum value of the highest tool
temperature
cutting speed

s
e

e

e0

shear stress
shear strain
shear strain rate
reference plastic strain

A
ae
ap
B
C
Fra
Frim
Frm
fz
L
m
n
Ta
Th
Tha
Thim

Tm
Tr
Thm

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