Precision Mould Bottom Milling of AISI-D2 Tool Steel

🕜 Efficiency - 2 times faster than that without ultrasonic | 📈 Quality - well-maintained | ⚙️ Tool Life - tool wear greatly reduced due to the reduction of cutting force
  • Difficulties in Machining
  • HIT Achievements
  • Industry Application
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What makes AISI-D2 Tool Steel difficult to machine?


AISI-D2 tool steel is rated approximately 60~62HRC for its hardness.  This material not only possesses high hardness, but also high strength and wear resistance.  It is widely used in mold manufacturing, especially for cold work die steel.

This material is also the typical wind-hardened steel and is currently the most ideal wear resistance of alloy tool steel.

However, due to its high hardness and toughness, it is hard to increase the machining efficiency while maintaining acceptable workpiece quality.  Let alone the stability in tool life.

 
 

☑️ AISI-D2 Tool Steel Machining Information

 
    AISI-D2 Tool Steel Machining 
  Information          
  Material   AISI-D2 tool steel
  Feature   Ap 1mm, Ae 0.12mm
  Process   Bottom milling  
  Ultrasonic Tool Holder        HSKE40-R01-06
  Rotating Speed   3,000 ~ 5,000 rpm
  Machine Tool Type   3-axis vertical machining center

 
ultrasonic-assisted bottom milling on AISI-D2 tool steel workpiece
(Figure 1. ultrasonic-assisted bottom milling on AISI-D2 tool steel workpiece)


ultrasonic-assisted bottom milling on AISI-D2 tool steel
(Figure 2. ultrasonic-assisted bottom milling on AISI-D2 tool steel)


HSK-E40 ultrasonic toolholder was used on AISI-D2 tool steel bottom milling
(Figure 3. HSK-E40 ultrasonic toolholder was used on AISI-D2 tool steel bottom milling)


 

HIT's Goal in Machining AISI-D2 Tool Steel


The goal is to enhance the machining efficiency and improve the stability in tool life, while maintaining great surface quality.


 

Ultrasonic-Assisted Machining AISI-D2 Tool Steel Results

 

AISI-D2 Tool Steel Bottom Milling : Machining Efficiency

With HIT Ultrasonic, the cutting speed can be raised 2 times faster than that without ultrasonic, resulting in the increase in feed rate.  Consequently, it only took half of the original processing time to complete the bottom milling of AISI-D2 tool steel.

 

AISI-D2 Tool Steel Bottom Milling : Workpiece Quality


comparison of bottom milling AISI-D2 tool steel workpiece surface quality between HIT ultrasonic and non ultrasonic
(Figure 4. comparison of bottom milling AISI-D2 tool steel workpiece surface quality between HIT ultrasonic and non ultrasonic)


Throughout the machining trials, HIT discovered that there was no direct influence of ultrasonic-assisted machining technology on the workpiece surface quality.

The key to better surface quality lies in the reduction of the size of processing path pitch.  When the size of processing path pitch was reduced, it indicated that the tool needed to run more processing paths to finish the entire process, which took even more processing time.

This is where HIT ultrasonic-assisted machining technology came for help!  The biggest benefit of HIT ultrasonic is to enhance the machining efficiency, so that even when the size of processing path pitch was reduced, the processing time would not have to take too long. 

 

AISI-D2 Tool Steel Bottom Milling : Tool Life


comparison of the tool wear between HIT ultrasonic and non ultrasonic bottom milling on AISI-D2 tool steel
(Figure 5. comparison of the tool wear between HIT ultrasonic and non ultrasonic bottom milling on AISI-D2 tool steel)


With the high-frequency micro-vibration of HIT ultrasonic, the reduction in cutting force helped reduce the tool wear when machining this kind of hard metal steel material.


 

HIT Ultrasonic Machining Technology Achievements


🕜 Efficiency - 2 times faster than that without ultrasonic
📈 Quality - well-maintained
⚙️ Tool Life - tool wear greatly reduced due to the reduction of cutting force


 

AISI-D2 Tool Steel Machining in Industry Application



Bottom milling AISI-D2 Tool Steel is often applied in the Precision Machinery industry, especially for optical precision molds, stamping dies, plastic molds, etc.


AISI-D2 tool steel is rated approximately 60~62HRC for its hardness.  This material not only possesses high hardness, but also high strength and wear resistance.  It is widely used in mold manufacturing, especially for cold work die steel.

This material is also the typical wind-hardened steel and is currently the most ideal wear resistance of alloy tool steel.

However, due to its high hardness and toughness, it is hard to increase the machining efficiency while maintaining acceptable workpiece quality.  Let alone the stability in tool life.


HIT's Ultrasonic Machining Module offers a comprehensive solution in machining these difficult-to-cut materials.  With the assistance of HIT's Ultrasonic Machining Technology, clients stopped worrying about poor surface quality and tool life.  Not only the surface quality and tool life can be improved, but the machining efficiency can also be greatly enhanced.  HIT assures its clients of matching up with their requirements and achieving even better outcomes!




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