Abstract
M3 is a newly improved cold die steel, an upgrade from the familiar cold die steel XW42. Only little information of these steel is available in literature for its machining characteristics since it is a newly improved die steel. This paper attempts to show the effects of machining factors on the responses consist of material removal rate (MRR), surface roughness (SR) and cutting speed (CS) of WEDM-ed M3 die steel. The machining factors that had been investigated were pulse on time (Ton), Voltage (V) and wire tension (WT). Other wire electrical discharge machine (WEDM) performance characteristics such as white layer thickness formation, microstructural and metallurgical alterations were also investigated. The technique of analysis of variance (ANOVA) was used to confirm the variables affecting the responses. The experimental results revealed that Ton, V and WT greatly influenced the MRR and SR. With high toughness of M3, no micro cracks were observed on the machined surface. Debris and craters were significantly reduced at low Ton, medium V and high WT. SEM analysis of white layer thickness exposed a deterioration about 53% from the base material (XW42) while maintaining the surface roughness at 192μm.
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