Abstract. This paper presents the morphology of built-up edge (BUE) formation under wet and dry conditions with low and high cutting speeds. The workpiece materials and cutting tools selected for this work were aluminium alloy and canela carbide inserts graded PM25. The cutting tools underwent turning operation machining tests and their performance was evaluated by the flank wear and observation of the tool wear area. The machining tests were conducted at different spindle speeds and feed rates while the cut depth was kept constant. The analysis showed that formation of the BUE was dominant at low cutting speeds in dry conditions, but in wet conditions at high cutting speeds, a better performance was exhibited in terms of wear analysis.

High Thermal Conductivity Steel-150 (HTC-150) is a specific steel designed for use in the hot stamping process as a stamping die. HTCS-150 die steel was difficult to machine due to its high strength, hardened state, and high thermal conductivity characteristics, which necessitated parameter control for a fine surface finish and maximum tool life. The characteristics of tool wear when machining HTCS-150 hardened steel (52 HRC) with a ball nose end mill TiAlN coated carbide insert is presented in this study. Cutting speed, feed rate, and axial depth of cut have all been varied in machining trials. Response surface methodology experimental design was used to create a parametric optimisation model. The results indicate that the model develops an accurate prediction, with comparisons between measured and expected results suggesting that the model operates within the 90% prediction interval with an error of less than 10%. The lowest tool wear was achieved at 130 m min−1 cutting speed, 0.4 mm/tooth feed rate, and 0.1 mm axial depth of cut, according to the optimisation results. The most influenced cutting parameters were found to be feed rate and depth of cut, followed by cutting speed. The wear surface texture analysis revealed coating delamination, adhesion, built-up edge formation, and tool edge chipping. The findings of this experimental study can be used to machine the HTCS-150 for the longest possible tool life while maintaining a fine surface finish.

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