Temperature effect on insert tool life in dry machining

Abstract: This thesis work researched the temperature effects the insert tool life. This was examined through physical laboratory testing with designed milling tools and temperature simulations in ANSYS. The designed milling tools altered the temperature in the insert through external parameters like design and material. Three milling tools were used in total: A milling tool created in an copper alloy that cools the inserts, a milling tool created in the material idun that increases the temperature in the inserts, and the milling tool Coro Mill 245 that was used as a reference. These tools were tested with two inserts, insert 1130 with a coating of PVD, and insert 4330 which has a coating of CVD.  The idun milling tool and the reference milling tool was already designed, but the copper milling tool was designed during the thesis work. The designed copper milling tool implemented a heat sink to cool the milling tool with convection and was manufactured in a copper alloy with high strength. The copper milling tool was 20 $\%$ colder than the reference milling tool when comparing the maximum temperature of the insert. Through testing in dry milling of the three milling tools with different inserts and a simulation in ANSYS of the temperature development, the conclusion was that insert 4330 had crater wear which increased with increased temperature. This crater wear can be the main factor in the insert tool life.