Effect of grey relational optimization of process parameters on surface and tribological characteristics of annealed AISI P20 tool steel machined using wire EDM

Abstract

To increase the productivity and quality of the machined components, wire electro-discharge machine parameters such as cutting speed, kerf width, and surface roughness are often optimized. The Wire-electro discharge machining process generates a much higher temperature at the wire-work piece interface which can potentially change the metallurgical characteristics of the machined surface. This paper studies the changes in the tribology of surface and sub-surface of the workpiece due to the initial and optimized wire-electro discharge machine parametric setting using grey relational analysis while machining sub-cooled AISI P20 tool steel. It is concluded that the optimum parametric setting to obtain a better cutting speed, kerf width, and surface roughness using grey relational analysis, which improves the productivity and quality of the component, also produces a thicker recast layer. The wear test revealed that the surface machined with an optimized parametric setting gives higher wear resistance. Detailed scanning electron microscopy explains the characteristics of the recast layer and micro-hardness explains the surface hardenability of tool steel, which is a result of martensitic transformation through rapid cooling, formed heat affected zone, and increase in oxygen content on the surface. The wear test proved that the recast layer helps in improving the wear resistivity of tool steel. The methodology of the hardening of the surface and the sub-surface layer can strengthen the application of components.

Effect of Heat‐Treatment and NiB–TiO2 Composite Coating on the Tribological Performance of AISI P20 Steel

“…Indeed, the defect‐free areas (1 and 4) practically reveal the same chemical elements (C, Si, Cr, Mn, and Fe) shown in Table 1, which is definitely the typical chemical composition of AISI P20 steel. However, the carbon content is somehow high in these areas (3.00 wt%), likely resulting from the breakdown of cementite into Fe and C, [ 44 ] subsequently leading to the formation of carbonate corrosion products. In addition to these chemical elements, the defected areas (2, 3, 5, and 6) expose further chemical elements, including oxygen (O) and sulfur (S), at high levels.…”

Recent Research in Wire Cut Electrical Discharge Machining Process

“…The surface machined with an optimal parametric setting yields higher wear resistance, according to the wear test results. [12] M. Veeranjaneyulu et al ,shown how the thickness of the work piece affected the MRR and surface roughness responses in the AL6063-T6 alloy's wire-edge electronic data milling.L8-Orthogonal array of Taguchi method was used to accomplish the procedure on aluminum alloy AL6063-T6. Surface roughness (Ra) and Material Removal Rate (MRR) are the quantifying responses, and the input parameters are workpiece thickness (w/p-t), pulse on time (Ton), pulse off time (Toff), wire tension (WT), wire feed (WF), and dielectric flushing pressure (WP).…”

Parametric Investigation of the Effects of Electrical Discharge Machining on Plain D2 Steel

“…While T significantly impacts MRR, its influence on EWR is subdued. This underscores the fact that while longer duty cycles can result in enhanced material removal, they do not necessarily correlate to a proportionate increase in electrode wear [63]. From the plot presented in Figure 7, it is evident that there are pronounced interactions among the parameters, primarily between Ip, Vg, Ton, and T. Here is a detailed interpretation of the interactions:…”