PSI - Issue 53

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ScienceDirect

Procedia Structural Integrity 53 (2024) 291–298 Structural Integrity Procedia 00 (2023) 000–000 Structural Integrity Procedia 00 (2023) 000–000

www.elsevier.com / locate / procedia www.elsevier.com / locate / procedia

© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons Abstract Achieving a mirror-like finish surface quality in plastic injection molds and dies is necessary for the manufacture of optical components in the automotive industry. Any defects present on the mold surface will be evidenced on the injected part, compromising the functionality of the final product. Moreover, the typically employed finishing techniques (milling and polishing) in mould steels can be excessively time-consuming. The identification of machining and polishing combinations that meet the demanding surface requirements while minimizing time and material resources is therefore essential for ensuring the e ffi ciency andcost-e ff ectiveness of the mould-making process. In this work, an experimental study was conducted on the milling of hardened tool steel using a 6 mm two flute ball nose end mill. Distinct configurations of axial and radial depths of cut as well as feed per tooth were considered and their impact on the pre-polishing surface roughness was analysed. A methodology for the parametrization of polishing conditions was developed, ensuring consistency of speed and pressure. Further tests were conducted to evaluate the relation between post-polishing surface quality and the total duration of the combined finishing approach. The polishing stage consisted on submitting the milled samples to SiC paper (800 and 1000 grit) and diamond cloth (6 and 3 µ m) polishing. The method provided enhanced control of the polishing operation and revealed milling / polishing improved sequences for attaining surface roughness technical requisites. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons. Keywords: Type your keywords here, separated by semicolons ; Abstract Achieving a mirror-like finish surface quality in plastic injection molds and dies is necessary for the manufacture of optical components in the automotive industry. Any defects present on the mold surface will be evidenced on the injected part, compromising the functionality of the final product. Moreover, the typically employed finishing techniques (milling and polishing) in mould steels can be excessively time-consuming. The identification of machining and polishing combinations that meet the demanding surface requirements while minimizing time and material resources is therefore essential for ensuring the e ffi ciency andcost-e ff ectiveness of the mould-making process. In this work, an experimental study was conducted on the milling of hardened tool steel using a 6 mm two flute ball nose end mill. Distinct configurations of axial and radial depths of cut as well as feed per tooth were considered and their impact on the pre-polishing surface roughness was analysed. A methodology for the parametrization of polishing conditions was developed, ensuring consistency of speed and pressure. Further tests were conducted to evaluate the relation between post-polishing surface quality and the total duration of the combined finishing approach. The polishing stage consisted on submitting the milled samples to SiC paper (800 and 1000 grit) and diamond cloth (6 and 3 µ m) polishing. The method provided enhanced control of the polishing operation and revealed milling / polishing improved sequences for attaining surface roughness technical requisites. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons. Keywords: Type your keywords here, separated by semicolons ; Third European Conference on the Structural Integrity of Additively Manufactures Materials (ESIAM23) Superfinishing of hardened steel for the moulding industry of automotive lighting parts Bruno Sousa a , Tiago Silva b, ∗ , Vitor Sousa a,b , Daniel Figueiredo a,b , Cristina Fernandes a,b , Alexandre Ferreira a,b , Ab´ılio de Jesus a,b a INEGI, Institute of Science and Innovation in Mechanical and Industrial Engineering, Rua Dr. Roberto Frias 400, 4200-465, PT b DEMec, Department of Mechanical Engineering, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465, PT c Palbit S.A., Rua das T´ılias s / n, 2850-582, PT d MD Moldes, Rua do Fagundo 211, 2400-016, PT Third European Conference on the Structural Integrity of Additively Manufactures Materials (ESIAM23) Superfinishing of hardened steel for the moulding industry of automotive lighting parts Bruno Sousa a , Tiago Silva b, ∗ , Vitor Sousa a,b , Daniel Figueiredo a,b , Cristina Fernandes a,b , Alexandre Ferreira a,b , Ab´ılio de Jesus a,b a INEGI, Institute of Science and Innovation in Mechanical and Industrial Engineering, Rua Dr. Roberto Frias 400, 4200-465, PT b DEMec, Department of Mechanical Engineering, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465, PT c Palbit S.A., Rua das T´ılias s / n, 2850-582, PT d MD Moldes, Rua do Fagundo 211, 2400-016, PT

∗ Corresponding author. Tel.: + 0-000-000-0000 ; fax: + 0-000-000-0000. E-mail address: tesilva@inegi.up.pt ∗ Corresponding author. Tel.: + 0-000-000-0000 ; fax: + 0-000-000-0000. E-mail address: tesilva@inegi.up.pt

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons 10.1016/j.prostr.2024.01.036 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons. 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ESIAM23 chairpersons.