Roughing of D2 tool steel material in its hardened state represents a real challenge in the die and mold industry. This paper examines the influence of D2 tool steel microstructure on carbide tool life and wear mechanisms. The detrimental effect of material high hardness (60 to 62 HRc) on tool life is augmented by the unique distribution of carbide particles in its microstructure. Tool wear analysis was performed using Scanning Electron Microscopy and chips produced were analyzed using optical microscopy. A numerical simulation of the milling process to predict the cutting temperature isotherms in the tool and workpiece completes the experimental observations. Results obtained from FEM were used to clarify the tool wear mechanisms.
