H13 hot-work die steel, with hardness up to 45HRC and above, is a critical material for high-stress applications such as die-casting and forging molds, yet its milling process is severely challenged by intense thermo-mechanical coupling, which accelerates tool wear, degrades surface integrity, and shortens tool life. While conventional optimization approaches, including improved tool coatings, cutting-parameter adjustment, and advanced cooling/lubrication, have been widely studied, they often fail to address the micro-scale friction and wear phenomena occurring directly at the tool-chip interface. In particular, crater (moon-crater) wear, a typical failure mode on the rake face, has seldom been utilized as a direct design reference for groove structures. The work aims to propose an original design strategy: a micro-groove structure fabricated on the rake face is geometrically derived from the natural morphology of crater wear. This crater-wear-morphology-based micro-groove, crater-adaptive micro-groove aims not only to buffer cutting impact and delay groove-wear initiation, but also to actively guide chip flow, reduce cutting temperature, and suppress multiple wear mechanisms, thereby extending tool service life in the milling of H13 steel. The micro-groove design and validation followed a systematic simulation-to-experiment workflow. Firstly, a 3D finite-element milling model was built in Deform software with actual cutting parameters (vc=150 m/min, ae=17 mm, ap=0.4 mm, fz=0.4 mm/z) to simulate the rake-face wear pattern of a conventional tool. The predicted wear-region coordinates were exported and imported into UG software, where the wear boundary was projected onto the rake face and transformed into a smooth, arc-depth micro-groove profile via surface-fitting and Boolean operations. Key groove dimensions of depth 0.1 mm, edge-to-tip distance 0.15 mm were determined based on prior experimental experience and simulated wear extents. Physical tool prototypes were then produced via powder-metallurgy compaction and coated with an identical PVD coating as the reference (original) tool to ensure a fair comparison. Experimental investigations comprised: (1) milling-force measurement under two parameter sets (Set a: vc= 100 m/min, ae=19 mm, ap=0.5 mm, fz=0.6 mm/z; Set b: vc=150 m/min, ae=25 mm, ap=0.2 mm, fz=0.6 mm/z) with a Kistler dynamometer; (2) FE-based temperature simulation under Set a conditions; and (3) segmented wear tests on both the hardened surface layer (4, 8, 12 min) and the base material (16, 40, 48, 64, 80 min) of H13 workpieces (160 mm × 30 mm × 100 mm). Wear dimensions were quantified with an ultra-depth-of-field microscope and wear mechanisms were characterized via scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). The results demonstrated that the micro-groove tool did not significantly alter the milling forces. The peak values and dynamic trends of Fx, Fy, and Fz remained highly consistent with those of the original tool. However, it achieved a marked reduction of approximately 20% in the maximum cutting temperature. Wear measurements showed consistently smaller wear values on the rake face, flank face (mainly the secondary flank), and tool tip. More importantly, the service life of the micro-groove tool was extended by about 50% for milling of the hardened layer and by 25% for milling of the base material. EDS analysis revealed that oxygen content on the rake face of the micro-groove tool was significantly lower, especially inside the micro-grooves, indicating suppressed oxidative wear. Furthermore, the micro-groove promoted chip curling with a smaller radius, shortening the tool-chip contact length by roughly 30% and thereby reducing heat accumulation and secondary wear caused by chip entanglement. Further analysis confirmed a direct correlation between the improvement in tool life and the effective control of peak cutting temperature. In conclusion, the crater-morphology-based micro-groove design alleviates thermo-mechanical coupling through a synergistic multi-mechanism action: (1) the concave structure buffers cutting impact, delaying the initiation and propagation of groove wear; (2) the increased effective rake angle and the promoted chip-to-chip friction inside the groove reduce direct tool-chip interaction and frictional heat generation; and (3) the guided chip curling minimizes contact duration and heat buildup. By effectively lowering the milling temperature, the tool inhibits oxidative, adhesive, and groove wear, leading to a substantial extension of service life. This work provides a novel, scientifically grounded approach for designing high-performance milling tools for difficult-to-machine materials such as H13 die steel, and it enriches the theoretical understanding of wear-suppression mechanisms in micro-structured cutting tools. The proposed design strategy offers practical potential for applications in aerospace, automotive, and precision mold manufacturing, where prolonged tool life and enhanced machining stability are critical.
Key words
design of micro-grooves on rake face /
crater morphology /
milling /
wear performance /
tool service life
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
References
[1] 张国庆. TiAlN涂层刀具高速铣削镍基高温合金过程中刀具损伤及刀具寿命研究[D]. 济南: 齐鲁工业大学, 2023.
ZHANG G Q.Study on Tool Damage and Tool Life during High-Speed Milling of Nickel-Based Superalloys Using TiAlN-Coated Tools[D]. Jinan: Qilu University of Technology, 2023.
[2] 李雪萍, 谭超林, 蔡盼盼, 等. YG6硬质合金上APA-Arc制备TiCN梯度膜结构及力学性能研究[J]. 硬质合金, 2016, 33(1): 1-7.
LI X P, TAN C L, CAI P P, et al.Microstructure and Mechanical Properties of Graded TiCN Hard Coating Deposited by APA-Arc Technology onto YG6 Cemented Carbide[J]. Cemented Carbide, 2016, 33(1): 1-7.
[3] 詹大年. 难加工材料曲面构件变齿距球头刀五轴铣削动力学建模与工艺参数优化[D]. 大连: 大连理工大学, 2024.
ZHAN D N.Dynamic Modeling and Process Parameter Optimization of Five-Axis Milling with Variable-Pitch Ball-End Mill for Curved Components of Difficult-to- Machine Materials[D]. Dalian: Dalian University of Technology, 2024.
[4] 安庆龙, 韦靖, 高斌, 等. 难加工材料微量润滑及低温辅助切削加工技术研究[J]. 工具技术, 2022, 56(7): 18-25.
AN Q L, WEI J, GAO B, et al.Research on Minimum Quantity Lubrication and Cryogenic Assisted Cutting of Difficult-to-Cut Materials[J]. Tool Engineering, 2022, 56(7): 18-25.
[5] WU Z, DENG J X, CHEN Y, et al.Performance of the Self-Lubricating Textured Tools in Dry Cutting of Ti-6Al-4V[J]. The International Journal of Advanced Manufacturing Technology, 2012, 62(9): 943-951.
[6] 犹大国, 何林, 周小容, 等. 微槽结构对前刀面润湿性能影响及参数优化[J]. 组合机床与自动化加工技术, 2024(7): 132-136.
YOU D G, HE L, ZHOU X R, et al.Influence of Micro-Groove Structure on Wettability of Front Tool Surface and Parameter Optimization[J]. Modular Machine Tool & Automatic Manufacturing Technique, 2024(7): 132-136.
[7] 何耿煌. 切屑折断分析及其直接断屑技术的研究[J]. 哈尔滨理工大学学报, 2016, 21(1): 6-12.
HE G H.Study on the Chip Breaking Analysis and Its Straight Breaking Technology[J]. Journal of Harbin University of Science and Technology, 2016, 21(1): 6-12.
[8] 何耿煌, 吴冲浒, 刘献礼, 等. 可转位刀片断屑槽断屑性能及其槽构技术研究[J]. 哈尔滨理工大学学报, 2015, 20(3): 13-18.
HE G H, WU C H, LIU X L, et al.Research on the Chip-Breaking Performance of Chip Breaker of Cemented Carbide Index-Able Insert and Its Groove Structure Technology[J]. Journal of Harbin University of Science and Technology, 2015, 20(3): 13-18.
[9] 刘锐. 断屑槽形状对硬质合金刀具切削性能的影响分析[J]. 机械制造, 2024, 62(1): 75-77.
LIU R.Influence Analysis of Chipbreaker Shape on Cutting Performance of Cemented Carbide Tool[J]. Machinery, 2024, 62(1): 75-77.
[10] ALTINKAYA E, GÜLLÜ A. AISI 316 Östenitik Paslanmaz Çeliğin İşlenmesinde Talaş Kırıcı Formunun Takım Aşınmasına ve Yüzey Pürüzlülüğüne Etkisi[J]. Politeknik Dergisi, 2008, 11(1): 13-17.
[11] YıLMAZ B, KARABULUT Ş, GÜLLÜ A. A Review of the Chip Breaking Methods for Continuous Chips in Turning[J]. Journal of Manufacturing Processes, 2020, 49: 50-69.
[12] ELKASEER A, LAMBARRI J, ANDER SARASUA J, et al.On the Development of a Chip Breaker in a Metal-Matrix Polycrystalline Diamond Insert: Finite Element Based Design with NS-Laser Ablation and Machining Verification[J]. Journal of Micro and Nano-Manufacturing, 2017, 5(3): 031007.
[13] REIS B C M, DOS SANTOS A J, DOS SANTOS N F P, et al. Cutting Performance and Wear Behavior of Coated Cermet and Coated Carbide Tools When Turning AISI 4340 Steel[J]. The International Journal of Advanced Manufacturing Technology, 2019, 105(1): 1655-1663.
[14] VERESCHAKA A, TABAKOV V, GRIGORIEV S, et al.Investigation of Wear Dynamics for Cutting Tools with Multilayer Composite Nanostructured Coatings in Turning Constructional Steel[J]. Wear, 2019, 420: 17-37.
[15] ZOU Z F, HE L, JIANG H W, et al. Development and Analysis of a Low-Wear Micro-Groove Tool for Turning Inconel 718[J]. Wear, 2019, 420/421: 163-175.
[16] JIANG H W, HE L, REN Z W, et al.Wear Mechanism of the Loose Layer on the Rake Face of a New Cemented Carbide Micro Groove Turning Tool[J]. The International Journal of Advanced Manufacturing Technology, 2018, 98(5): 1069-1080.
[17] QIU L C, DU Y, WU L Y, et al.Microstructure, Mechanical Properties and Cutting Performances of TiSiCN Super-Hard Nanocomposite Coatings Deposited Using CVD Method under the Guidance of Thermodynamic Calculations[J]. Surface and Coatings Technology, 2019, 378: 124956.
[18] 王立强, 赵健明, 樊湘芳, 等. 热轧态H13钢调质工艺参数模拟计算与实验验证[J]. 南华大学学报(自然科学版), 2023, 37(3): 59-64.
WANG L Q, ZHAO J M, FAN X F, et al.Simulation Calculation and Experimental Verification of Tempering Process Parameters of H13 Steel in Hot Rolled Condition[J]. Journal of University of South China (Science and Technology), 2023, 37(3): 59-64.
[19] 张家涛, 钟毅, 孙淑红, 等. 压铸用H13热作模具钢热处理工艺研究[J]. 特种铸造及有色合金, 2009, 29(3): 237-239.
ZHANG J T, ZHONG Y, SUN S H, et al.Heat Treatment of H13 Hot Working Die Steel for Die Casting[J]. Special Casting & Nonferrous Alloys, 2009, 29(3): 237-239.
[20] 陶琪. 考虑材料硬度影响的切削机理分析及切削仿真平台开发[D]. 长沙: 湖南大学, 2017.
TAO Q.Analysis of Cutting Mechanism Considering Material Hardness and Development of Cutting Simulation Platform[D]. Changsha: Hunan University, 2017.
[21] 孙轼龙, 朱学明, 任保民. 金刚石涂层刀具铣削氧化锆义齿性能研究[J]. 硬质合金, 2016, 33(5): 342-349.
SUN S L, ZHU X M, REN B M.Research on Cutting Performance of Diamond Coated Tools for Zirconia Denture[J]. Cemented Carbide, 2016, 33(5): 342-349.
[22] 姜芙林. 高速断续加工过程工件及刀具瞬态切削温度的研究[D]. 济南: 山东大学, 2015.
JIANG F L.Investigation of Transient Cutting Temperature of Workpiece and Cutting Tool in High Speed Intermittent Machining Process[D]. Jinan: Shandong University, 2015.
[23] 罗欢, 张定华, 罗明. 航空难加工材料切削刀具磨损与剩余寿命预测研究进展[J]. 中国机械工程, 2021, 32(22): 2647-2666.
LUO H, ZHANG D H, LUO M.Tool Wear and Remaining Useful Life Estimation of Difficult-to-Machine Aerospace Alloys: A Review[J]. China Mechanical Engineering, 2021, 32(22): 2647-2666.
[24] YANG H C, CHEN Z T, ZHOU Z T.Influence of Cutting Speed and Tool Wear on the Surface Integrity of the Titanium Alloy Ti-1023 during Milling[J]. The International Journal of Advanced Manufacturing Technology, 2015, 78(5): 1113-1126.
[25] LI W, GUO Y B, GUO C S.Superior Surface Integrity by Sustainable Dry Hard Milling and Impact on Fatigue[J]. CIRP Annals-Manufacturing Technology, 2013, 62(1): 567-570.
[26] CEDERGREN S, OLOVSJÖ S, SJÖBERG G, et al. The Effects of Grain Size and Feed Rate on Notch Wear and Burr Formation in Wrought Alloy 718[J]. The International Journal of Advanced Manufacturing Technology, 2013, 67(5): 1501-1507.
[27] CHOWDHURY S, BOSE B, ARIF A F M, et al. Improving Coated Carbide Tool Life through Wide Peening Cleaning (WPC) during the Wet Milling of H13 Tool Steel[J]. Wear, 2020, 450: 203259.
[28] PRADO M T, PEREIRA A, PÉREZ J A, et al. Methodology for Tool Wear Analysis by a Simple Procedure during Milling of AISI H13 and Its Impact on Surface Morphology[J]. Procedia Manufacturing, 2017, 13: 348-355.
[29] 吕宏刚. H13钢硬态铣削过程中的刀具磨损及其对表面完整性的影响[D]. 济南: 山东大学, 2012.
LYU H G.Tool Wear and Its Influence on Surface Integrity During Hard Milling of H13 Steel[D]. Jinan: Shandong University, 2012.
[30] 解长鹏, 刘国东, 刘祁文, 等. 沟槽微织构硬质合金刀具的摩擦仿真分析[J]. 工具技术, 2022, 56(2): 43-47.
XIE C P, LIU G D, LIU Q W, et al.Attrition Simulation Analysis of Carbide Tool with Groove Microtexture[J]. Tool Engineering, 2022, 56(2): 43-47.
[31] 姜莉莉. 基于激光工艺制备的表面微织构齿面摩擦性能研究[D]. 厦门: 厦门理工学院, 2020.
JIANG L L.Research on Friction Properties of Micro-Textured Tooth Surface Based on Laser Technology [D]. Xiamen: Xiamen University of Technology, 2020.
[32] 郝秀清, 宋晓路, 李亮. 表面织构化刀具的研究现状与进展[J]. 表面技术, 2016, 45(9): 170-181.
HAO X Q, SONG X L, LI L.Development and Perspective of Surface Texturing Tools[J]. Surface Technology, 2016, 45(9): 170-181.
[33] 梁志强, 李蒙招, 陈碧冲, 等. 基于微磨削方法的微织构刀具制备与切削性能研究[J]. 表面技术, 2020, 49(2): 143-150.
LIANG Z Q, LI M Z, CHEN B C, et al.Fabrication and Cutting Performance of Micro-Textured Tools Based on Micro-Grinding[J]. Surface Technology, 2020, 49(2): 143-150.
Funding
The National Natural Science Foundation of China (2502140, 52565047); Guizhou Province Science and Technology Achievement Transformation Project (Qianke Huoju [2025] Major 106, Qianke Huoju [2025] General 017); Science and Technology Innovation Platform Research Project of Guizhou Province (Qianke Huoju Platform CXPTXM [2025]008)
PDF(15851 KB)
