Abstract
In this study, plasma shot (PS) treatment was applied to high-speed steel (HSS) surfaces using a titanium carbide electrode to confirm the effect of discharge current (Ip) on the formation of a single dimple and analyze a modified layer. The roughness of modified surfaces increased when Ip increased, and energy-dispersive X-ray spectrometry showed an increase in titanium atom density when Ip and electrode consumption volume (Ve) increased. A friction test confirmed that the modified surface’s friction was reduced by discharge dimples under low-load conditions. Vickers hardness test confirmed that the hardness of the modified surface was ~ 300–600 HV higher than that of an untreated HSS surface. Moreover, it increased with an increase in Ip. However, application of PS treatment to the edge of surfaces on the workpiece caused shape deterioration. The deterioration size of the edge of the modified layer increased when Ip increased. To solve this issue, we propose a novel method named position-adjusted PS (PA-PS) treatment. PA-PS treatment is used to adjust the end of the electrode in the order of tens of micrometers from the edge of the workpiece to avoid the deterioration of the edge form. Under Ip = 21 A, PA-PS formed a modified layer without deteriorating the edge shape of the workpiece, thus confirming the PS characteristics applied to HSS surfaces. Moreover, PA-PS treatment solved the shape deterioration of the edge on modified surfaces via PS treatment.
Highlights
At present, products that have considerably improved our standard of living are produced by various manufacturing methods
Sku is the sharpness of the surface, while Ssk is the symmetry of the surface and characterizes height distribution [14]
The surface treated under Ip = 10 A and 21 A has Sku < 3, which indicates a dull roughness of shape
Summary
Products that have considerably improved our standard of living are produced by various manufacturing methods. The industry depends on the machining process to machine the various shapes of products using cutting tools. PS treatment was developed by applying electric discharge machining (EDM). EDM is a manufacturing method that can be used to machine hard materials into complex shapes with high precision [4]. PS treatment is completely the opposite of EDM and transfers electrode materials to the workpiece surface to form modified surfaces. In this process, arc discharges occur between the workpiece and the electrode, which partially melts and transfers to the workpiece
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