Originally Posted by
roninB4
thermal stress i dont know is an issue with hard milling techniques, as both the tool and work piece stay cold during machining. the chips come off molten. maybe im wrong though.
-You may be right, it depends upon how much material you're removing. Any punch/die section I had to make required more material removal than could be done in a single pass. Sure the chip was blue but there was plenty of heat left in the workpiece. Now if you're just sharpening the punch/die section that's only .010-.030 and nowhere near as much material removed as new tool construction. Then again, your die may not require enough material removed to create the sort of heat I'm talking about. You've seen the die so your experience trumps my estimation.
cost of the carbide tools seems negligable, as it takes the same tool to mill the unhardened steel in the first place, and tool life isnt shortened significantly. we also eliminate coolant, which is another cost savings.
-We return to the amount of material removed. The level of detail figures in here but you must have covered that already.
sharpness of the corners is a big concern. the piece i milled (not d2 mind you) left what appears to be a sharp edge, with minimal burr. i havent looked at it under a microscope though. it would obviously need a small amount of hand work though. i dont know if that negates the savings.
-If you haven't milled D2 that's already hardened then you should experience the joy that can only come from milling hardened D2, it's right up there with Ferro-Tic and Waspalloy in terms of sheer machining pleasure. All BS aside, the burr can be tough to remove. If your cutter has rotation into the edge instead of exiting at the edge (does that make sense?) it has less tendency to push/wipe material out over the edge, thereby creating a burr. Hand finishing will depend upon the geometry of the workpiece and the amount of difficulty will be inversely proportionate to the amount of available time. You may also find that some stones will just "skate' across hardened D2 and you'll need to find some that are soft enough to bite into it. You shouldn't need a microsope to examine the cutting edge, a 10x loupe will be good enough unless the die is expected to have production runs of +1,000,000 hits between sharpenings. I applaud somebody trying to explore outside the conventional methods and hope it works out for you, do let me know if you find success with your methods. Good luck.