Experimental and FEA study is conducted to get an insight into critical mechanisms of temperature, deformation, stress generation and variations with cutting speed and tool wear in hard milling AISI H13 steel (50±1 HRC). The critical issues like energy consumption during milling and the resulting surface integrity of the machined component depend on the tool and workpiece interaction. An insight into tool and workpiece interaction is needed in order to design a better milling process for required surface integrity. 2D finite element simulation of orthogonal cutting model is performed to investigate the variations of temperatures and residual stresses at different cutting speeds and tool wears. Hard milling experiments are conducted to correlate with the simulation results. The fact that in hard milling, the temperature does not penetrate deep into the workpiece and there is no clear evidence of heat affected zone such as white layer is demonstrated. With the finite element simulations and experiments, the capability of hard milling process to achieve better surface integrity on the machined surface is explored.

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