An Experimental Effect of Soft Brass Wire on MRR, Kerf Width and Surface Roughness of AISI D2 Tool Steel In WEDM

One of the non-conventional machining processes widely used in the industry is the wire electrical discharge machining (WEDM). This process has many advantages, like the great precision and quality that can be achieved. As well as other manufacturing operations, the success of the process relies on a correct selection of the cutting parameters. The present paper outlines an experimental study to optimize the machining time and the surface roughness in WEDM of AISI D2 tool steel during roughing machining. The Taguchi methodology is used to evaluate the effects and contributions of the pulse-on time, pulse-off time, servo voltage, and wire speed, on the response variables. The desirability method is employed to define a set of cutting parameters that allows reducing both machining time and surface roughness at the same time. The pulse-on time is the most significant factor for reducing the machining time, followed by the servo voltage, the pulse-off time and the wire speed. For surface roughness, the pulse-off time is the factor with the greatest influence over the response variable. The results obtained show that the machining time is reduced by 4.65%, and the surface roughness is diminished by 4.60% when compared with the initial values that are commonly used in the machining of AISI D2 tool steel. Therefore, greater production rates can be achieved without compromising the quality of the machined parts.

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Prediction of Surface Roughness in Hard Milling of AISI D2 Tool Steel

Proceedings of International Conference on Leading Edge Manufacturing in 21st century LEM21 ◽

10.1299/jsmelem.2007.4.7a108 ◽

2007 ◽

Vol 2007.4 (0) ◽

pp. 7A108

Author(s):

M.A. LAJIS ◽

A.N. Mustafizul KARIM ◽

A.K.M. Nurul AMIN ◽

A.M.K. HAFIZ

Keyword(s):

Surface Roughness ◽

Tool Steel ◽

Hard Milling ◽

Aisi D2 ◽

Aisi D2 Tool Steel

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Analysis of Micro-Milling of Hardened Tool Steel

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.686.57 ◽

2016 ◽

Vol 686 ◽

pp. 57-62 ◽

Cited By ~ 2

Author(s):

Branislav Sredanovic ◽

Gordana Globocki Lakic ◽

Davorin Kramar ◽

Janez Kopac

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Tool Steel ◽

Micro Milling ◽

Milling Cutter ◽

Working Length ◽

Aisi D2 ◽

Hardened Tool Steel ◽

Aisi D2 Tool Steel ◽

Intensive Development

The development of industry in the last ten years has caused the production of parts with relatively small dimensions. This has led to intensive development of efficient micro-technologies through research of processes, machines and tools. This paper presents the research of machinability, channels micro-milling in AISI D2 tool steel (X155CrVMo-5), hardened to 62 HRc. As the tool is used micro-milling cutter with diameter of 0.6 mm and relatively large working length of 5 mm. Analysis of surface roughness, burr on workpiece edges and reduction of cutter diameter due tool wear was performed.

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2308 Effect Cutting Parameters on Surface Roughness during End Milling of AISI D2 Tool Steel

The Proceedings of Design & Systems Conference ◽

10.1299/jsmedsd.2014.24._2308-1_ ◽

2014 ◽

Vol 2014.24 (0) ◽

pp. _2308-1_-_2308-6_

Author(s):

Mohd Amal ABD. HALIM ◽

Mohd Shahir KASIM ◽

Mohd Amri SULAIMAN ◽

Effendi MOHAMAD ◽

Teruaki ITO

Keyword(s):

Surface Roughness ◽

Tool Steel ◽

End Milling ◽

Cutting Parameters ◽

Aisi D2 ◽

Aisi D2 Tool Steel

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Tool Wear and Surface Roughness in Machining AISI D2 Tool Steel

Indian Journal of Science and Technology ◽

10.17485/ijst/2016/v9i18/88731 ◽

2016 ◽

Vol 9 (18) ◽

Cited By ~ 2

Author(s):

Nik Faizu Kundor ◽

Norazmira Wati Awang ◽

Nawi Berahim

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Tool Steel ◽

Aisi D2 ◽

Aisi D2 Tool Steel

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A comparative study on surface topography and micro hardness of laser polished hardened AISI D2 tool steel

10.21203/rs.3.rs-929800/v1 ◽

2021 ◽

Author(s):

Zuofa Liu ◽

Jie Zhou ◽

Hang Wang ◽

Qiuyun Wang ◽

Qiang Liang ◽

...

Keyword(s):

Surface Roughness ◽

Surface Treatment ◽

Surface Topography ◽

Tool Steel ◽

Laser Surface ◽

Laser Surface Treatment ◽

Laser Polishing ◽

Aisi D2 ◽

Aisi D2 Tool Steel ◽

Polishing Efficiency

Abstract In this work, a laser polishing-hardening (LPH) method with integration and high efficiency for the treatment of AISI D2 tool steel was proposed, and the effects of laser hardening (LH), laser polishing (LP) and LPH treatments on the surface topography and microhardness were examined. The results show that LH method had a negligible effect on the surface roughness of the treated sample, while the surface roughness Ra of LP and LPH specimens was reduced by 74.6% and 80.9% respectively, indicating that the milled surface topography had been significantly improved, especially LPH was more effective in reducing the roughness. Besides, the polishing efficiency of LPH was 10 times that of LP approach. In terms of hardness improvement, the near-surface microhardness of LH and LPH samples increased by 1.5 times and 1.3 times respectively, and the effective hardened zone (EHZ) depth was 0.42 mm and 0.24 mm respectively, demonstrating that these two laser processing methods had a beneficial effect on the cross-section microhardness of D2 tool steel, while the increase of LP on the microhardness was insignificant. The comprehensive analysis of the surface morphology and microhardness of LPH specimen indicates that LPH was a feasible laser surface treatment method for D2 tool steel. On the premise of ensuring a high surface finish, the polishing efficiency can be remarkably improved, the subsurface microhardness and EHZ depth of processed specimen can be also significantly enhanced, which provided a feasible idea for the application of laser surface treatment technology in industrial mold production.

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Multiresponse Optimization of Edm Process with Nanofluids Using Topsis Method and Genetic Algorithm

Archive of Mechanical Engineering ◽

10.1515/meceng-2016-0003 ◽

2016 ◽

Vol 63 (1) ◽

pp. 45-71 ◽

Cited By ~ 9

Author(s):

S. Prabhu ◽

B. K. Vinayagam

Keyword(s):

Genetic Algorithm ◽

Surface Roughness ◽

Regression Model ◽

Tool Steel ◽

Machining Process ◽

Machining Parameters ◽

Topsis Method ◽

Aisi D2 ◽

Aisi D2 Tool Steel ◽

Edm Process

Abstract Electrical Discharge Machining (EDM) process with copper tool electrode is used to investigate the machining characteristics of AISI D2 tool steel material. The multi-wall carbon nanotube is mixed with dielectric fluids and its end characteristics like surface roughness, fractal dimension and metal removal rate (MRR) are analysed. In this EDM process, regression model is developed to predict surface roughness. The collection of experimental data is by using L9 Orthogonal Array. This study investigates the optimization of EDM machining parameters for AISI D2 Tool steel using Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) method. Analysis of variance (ANOVA) and F-test are used to check the validity of the regression model and to determine the significant parameter affecting the surface roughness. Atomic Force Microscope (AFM) is used to capture the machined image at micro size and using spectroscopy software the surface roughness and fractal dimensions are analysed. Later, the parameters are optimized using MINITAB 15 software, and regression equation is compared with the actual measurements of machining process parameters. The developed mathematical model is further coupled with Genetic Algorithm (GA) to determine the optimum conditions leading to the minimum surface roughness value of the workpiece.

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