Analysis and Respond Surface Methodology Modeling on Property and Performance of Two-Dimensional Gradient Material Laser Cladding on Die-cutting Tool.

Guofu Lian,Xu Huang,Yang Zhang,Mingpu Yao

doi:10.3390/ma11102052

Guofu Lian, Xu Huang + Show 2 more

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https://doi.org/10.3390/ma11102052

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Abstract

Die-cutting tools have been widely applied in industrial production. However, different forms of failure on a blade, such as wear and fracture, can greatly reduce its service life. In this research, the die-cutting tool was selected as the object, a mixture of high speed steel powder and 304 stainless steel powder was coated as a gradient cladding layer onto the surface of AISI/SAE 1045 steel by laser cladding. The central composition design of the response surface methodology was adopted to establish a mathematical model between the pore area of the multi-layer, multi-track cladding, and its processing parameters: Laser Power (LP), Scanning Speed (SS), Gas Flow (GF), and Overlapping Rate (OR). This model was validated by variance analysis and inspection indicators. The actual experiment value by processing parameters optimization for achieving the smallest pore area showed a 4.41% error compared with the predicted value. The internal structure of the cladding layer is uniform. The defects, such as pores and cracks, meet the requirements. The wear resistance on the cutting edge is about 4.5 times compared with the substrate. The results provide a theoretical guidance for the controlling and prediction of the laser cladding forming quality on a two-dimensional gradient material and the optimization of the processing parameters.

Highlights

Die-cutting machines have been widely used in printing, packaging, digital accessories for mobile phones, medical supplies, electronic labels, and many other industries
The rotary die cutting machine utilizes the rotation of the rolling die and the continuous feed of the material by the feeding roll to complete the production by die-cutting with the interaction between material and cutting edge
Since high speed steel powder (W6Mo5Cr4V2) processes have outstanding thermoplastic properties and wear resistance, it is usually selected as the material for the cutting tool [26]. 304 stainless steel is resistant to high temperatures up to 800 ◦ C when its hardness as a cutting edge is satisfied to fulfill the cutting job

Summary

Introduction

Die-cutting machines have been widely used in printing, packaging, digital accessories for mobile phones, medical supplies, electronic labels, and many other industries. The rotary die cutting machine utilizes the rotation of the rolling die and the continuous feed of the material by the feeding roll to complete the production by die-cutting with the interaction between material and cutting edge. The hardness and wear resistance of die-cutting tools restrict the performance improvement of die-cutting equipment. The technical bottleneck of the die-cutting machine can be solved by effectively improving cutter body toughness and edge hardness, and enhancing the wear resistance, deformation resistance, and fracture resistance. Large scale cutting tools, such as die-cutting tools, would require stiffness property on its cutting edge to guarantee cutting quality and relatively less internal stiffness to prevent chipping on the Materials 2018, 11, 2052; doi:10.3390/ma11102052 www.mdpi.com/journal/materials

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