Using a DoE for a comprehensive analysis of the surface quality and cutting speed in WED-machined hadfield steel

Mouralová, Kateřina; Beneš, Libor; Bednár, J; Zahradníček, Radim; Prokeš, Tomáš; Matoušek, Radomil; Hrabec, Pavel; Fišerová, Zuzana; Otoupalík, Jan

doi:10.1007/s12206-019-0437-4

Cited by 22 publications

(12 citation statements)

References 22 publications

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“…The surface is relatively smooth, especially when compared to the surface of Sample 25 (the highest roughness values) shown in Figure 6b. This and almost all other produced samples are covered with a recast layer formed by a structure that is specific to special types of steels such as Hadfield [24].…”

Section: Analysis Of the Machined Surface And Discussionmentioning

confidence: 99%

“…The subsurface layer analysis was performed using electron microscopy on the pre−prepared metallographic specimens of all samples. This analysis is very important, since after WEDM, the defects in the form of cracks [13] or burnt cavities [24] are often found in the subsurface area, which can affect the correct functionality and durability of the part produced. The cross sections were observed using a Lyra3 scanning electron microscope.…”

Section: Analysis Of the Machined Surface And Discussionmentioning

confidence: 99%

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The Influence of WEDM Parameters Setup on the Occurrence of Defects When Machining Hardox 400 Steel

et al. 2019

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The unconventional technology wire electrical discharge machining is a highly used technology for producing precise and indented shaped parts of all materials that are at least electrically conductive. Its wide use makes this technology applicable in almost all branches of industry, even in the automotive industry, where the abrasion resistant material under investigation Hardox 400 steel is widely used for the manufacturing of truck bodies. The aim of this study was a comprehensive analysis of the machinability of this material using WEDM employing a 33−round experiment. Based on the change in machine parameters (pulse off time, gap voltage, discharge current, pulse on time, and wire feed), the cutting speed, the topography of machined surfaces, and the chemical composition of the workpiece surface, the morphology and condition of the subsurface layer including lamella production and a subsequent determination of the distribution of individual elements in the given area were analyzed. It has been found that during the machining of this steel, many defects occur in the subsurface layer of the material in the form of cracks with a depth of up to 22 µm and burned cavities. However, by appropriately adjusting the machine parameters, it was possible to completely remove these cracks.

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Section: Analysis Of the Machined Surface And Discussionmentioning

confidence: 99%

Section: Analysis Of the Machined Surface And Discussionmentioning

confidence: 99%

The Influence of WEDM Parameters Setup on the Occurrence of Defects When Machining Hardox 400 Steel

et al. 2019

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“…Abdulkareem et al [26] worked to enhance the SR because of more adhesion of the debris particles and surface irregularities on the processed surface. Mouralova et al [27] concluded that the frequency of discharge occurrence of the recast layer is highly influenced by cutting speed. Negrete [28] made a similar finding on AISI 01 tool steel.…”

Section: Introductionmentioning

confidence: 99%

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Khan

Rehman

Farooq

et al. 2021

Metals

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Recently, DC53 die steel was introduced to the die and mold industry because of its excellent characteristics i.e., very good machinability and better engineering properties. DC53 demonstrates a strong capability to retain a near-net shape profile of the die, which is a very challenging process with materials. To produce complex and accurate die features, the use of the wire electric discharge machining (WEDM) process takes the lead in the manufacturing industry. However, the challenge is to understand the physical science of the process to improve surface features and service properties. In this study, a detailed yet systematic evaluation of process parameters investigation is made on the influence of a wire feed, pulse on duration, open voltage, and servo voltage on the productivity (material removal rate) and material quality (surface roughness, recast layer thickness, kerf width) against the requirements of mechanical-tooling industry. Based on parametric exploration, wire feed was found the most influential parameter on kerf width: KW (45.64%), pulse on time on surface roughness: SR (84.83%), open voltage on material removal rate: MRR (49.07%) and recast layer thickness: RLT (52.06%). Also, the optimized process parameters resulted in 1.710 µm SR, 10.367 mm3/min MRR, 0.327 mm KW, and 10.443 µm RLT. Moreover, the evolution of surface features and process complexities are thoroughly discussed based on the involved physical science. The recast layer, often considered as a process limitation, was explored with the aim of minimizing the layers’ depth, as well as the recast layer and heat-affected zone. The research provides regression models based on thorough investigation to support machinists for achieving required features.

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“…Die-sinking EDM is a technological process where it is necessary to ensure machining efficiency and maximize the material removal rate while maintaining excellent surface and subsurface quality. To investigate in detail all the input factors affecting the erosion process of various types of steel, extensive research has been conducted including the influence of the cutting orientation of the semi-product, depending on its heat treatment for X210Cr12 steel [21], Hadfield machinability analysis [22], Creusabro [23], and Hardox steel [24] by using the design of experimentsand analysis of durability due to the occurrence of surface and subsurface defects [25]. The purpose of this study was a complex analysis of EDM-machined surfaces of individual experimental samples concerning the state of the subsurface area and formed defects.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

et al. 2020

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Die-sinking electric discharge machining (EDM) is an indispensable technological operation, especially in the production of molds and all internal and external shapes and cavities. For this reason, the effect of machine parameter settings (open-voltage, pulse current, pulse on time, and pulse off time) on the machining of two types of steels, 1.2363 and 1.2343ESR, was carefully investigated using graphite or copper electrodes in 10 mm × 10 mm or 100 mm × 100 mm shapes. For this purpose, a two-level half factor experiment was performed with one replication at the corner points and two replications at the central points, with a total of 80 rounds. The subject of the evaluation was the topography and morphology of machined surfaces including a detailed analysis of surface and subsurface defects in the form of cracks including the creation of regression equations describing the probability of crack occurrence. Furthermore, a study of the local hardness change in the subsurface area was performed, and lamellas were also made and studied by transmission electron microscopy. It has been found that by using die-sinking EDM, it is possible to effectively predict the probability of cracking on machined surfaces and also on machine 1.2363 and 1.2343ESR steels with a very good surface quality of Ra 1.9 and 2.1 µm using graphite electrodes. These findings will ensure the production of parts with the required surface quality without cracks, which is a crucial aspect for maintaining the required functionality and service life of the parts.

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Using a DoE for a comprehensive analysis of the surface quality and cutting speed in WED-machined hadfield steel

Cited by 22 publications

References 22 publications

The Influence of WEDM Parameters Setup on the Occurrence of Defects When Machining Hardox 400 Steel

The Influence of WEDM Parameters Setup on the Occurrence of Defects When Machining Hardox 400 Steel

A Detailed Machinability Assessment of DC53 Steel for Die and Mold Industry through Wire Electric Discharge Machining

Analysis of Machinability and Crack Occurrence of Steels 1.2363 and 1.2343ESR Machined by Die-Sinking EDM

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