Optimization of Process Parameters for Machining of Steel Molds used for Aluminum Casting in Wheel Industry

Abstract

The wheel industry, employing low-pressure casting techniques for producing lightweight alloy wheels, operates within a highly competitive manufacturing environment with significant production volumes. To fabricate essential mold core components for the aluminum wheel casting process, hot work tool steel alloys are selected for their exceptional durability and resistance to wear, fatigue, distortion, and high-temperature plastic deformation. Efficient machining operations for these steel molds require identifying optimal parameter combinations to minimize tool wear, surface roughness, and energy consumption while maximizing material removal rates. This study focuses on determining such parameters, utilizing DIN 1.2367 steel, to enhance manufacturing efficiency and meet industry requirements. The effects of machining parameters such as cutting speed, depth of cut, and number of inserts were investigated using the design of experiments. Depth of cut was determined as the most influential factor on tool wear, revealing the optimum parameter as 0.4 mm, followed by cutting speed. Notably, the number of inserts exhibits minimal direct impact but interacts significantly with the depth of cut, influencing wear patterns. This research contributes to sustainable machining practices by enhancing mold core manufacturing efficiency, prolonging tool life, and reducing tool wear. Such advancements are vital for the long-term competitiveness and environmental stewardship of the wheel industry.