Currently, due to the development of technology, the industry is proceeding with the development of advanced materials with high performance such as light weight, heat resistance and electric conductivity. Carbon Fiber Reinforced Plastics (CFRP) is an excellent material with high heat resistance, high strength and thermal shock resistance. In order to obtain excellent hole shape in CFRP drilling, we compared the modified drill shape and the conventional carbide drill. On the other hand, we determine the proper helix angle by observing the CFRP surface according to the helix angle at the trimming of the end mill proceeding after the hole machining.

To improve life time of machine components, higher alloy grade materials are used by adding more metal alloy components and content. Also production processes are further complicated and subdivided such as the forging, preliminary heat treatment, quality heat treatment, rough machining and finished machining process. Those reasons become major cause of large stress in the materials, and the residual stress generated during the manufacturing process causes fatal defects, such as crack, surface tear, warping and deformation of the products. It is necessary to evaluate the residual stress on the entire processes, from forging process to final finished machining process. Also in order to avoid those problems caused by residual stresses, it is necessary to know in advance what process is important to be controlled and what parameters affect residual stress. By the hole drilling method, residual stress was measured in each manufacturing process step. In this study, the hardness of the surface, the cutting force test and the metal analysis were performed to clarify the influence of manufacturing process parameters.

As product diversity increases and product life cycle gets shorter, lead time reduction and manufacturing cost saving of die & mold are getting important in machinery, automotive, and electronics industries. To develop a novel free-machining die & mold steel, we try to modify the chemical compositions of AISI P20 mold steel by adding boron, nitride, and sulfur. After making three types of mold steels which are base metal of AISI P20 mod., boron and nitrogen added, and boron, nitrogen, and sulfur added to the base metal. Milling tests are carried out using TiN, TiCN, and TiAlN coated WC end-mills under various cutting conditions. Boron and nitrogen added steel machined by TiN coated tool shows the most excellent tool wear and surface roughness characteristics. The results might come from BN inclusions in base metal acting as a stress concentration source and lowering strain resistance during cutting process. The relationship between tool wear and surface roughness are also discussed including feed rate effects.