Research on feasible region of specific cutting energy and surface roughness in high-speed dry milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts

Existing researches on coated tools do not provide predicted data about machining performance while exploring their changing rules. Meanwhile, the traditional cutting process parameters neither guarantees the surface quality of the 30CrMnSiNi2A nor attains high material removal rate (MRR). Accurate control and prediction of workpiece three-dimensional surface roughness ( S q ) and specific cutting energy consumption (SCEC) play an important role in improving the quality, reducing the cost of workpieces, and improving the processing efficiency. In this paper, according to the new SCEC geometric calculation approach and the influence of measuring position on S q , the SCEC and S q values can be accurately obtained. Then, based on the idea of the fitting formula, the influence of cutting parameters on SCEC and S q in high-speed dry (HSD) milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts is analyzed. Finally, the SCEC and S q prediction models considering coating type, cutting speed, feed per tooth, and cutting width are established by using the XGBoost algorithm. The R 2 values of SCEC and S q are 0.92465 and 0.91527, respectively, indicating that the model has a good prediction effect on experimental data. The feasibility of HSD milling of 30CrMnSiNi2A steel with CVD and PVD coated inserts is verified by analyzing SCEC, S q , and cutting temperature, which provides an experimental basis for high efficiency and high precision machining of 30CrMnSiNi2A steel.