Response surface methodology based parametric study for AISI H13 die steel using customized designed 3D printed Ti64 multi-nozzle polishing tool

Abstract

The work presents a study on FJP polishing of AISI H13 die steel using 3D printed multi nozzle (dual orifice) polishing tool and Silicon Carbide (SiC) abrasive slurry. It presents a simultaneous effect of feed rate and spindle rotation on the percentage change in surface roughness (%[Formula: see text]). Central Composite Design (CCD) method was used to design the experimentation plan and Analysis of Variance (ANOVA) was performed to evaluate the optimum values of the process parameters. The regression model developed for the FJP process was validated by polishing the AISI H13 workpiece with 39[Formula: see text] average initial surface roughness with the optimized process parameters; feed rate of [Formula: see text] and spindle rotation of [Formula: see text]. The optimized FJP parameters were able to generate the surface roughness of [Formula: see text]. The results obtained from the confirmatory experiments were found to be very close to the predicted results which validated the developed regression model. To further enhance the polishing efficiency, the optimum process parameters were used to polish AISI H13 die steel workpiece, the surface roughness was reduced from 390 to 110 nm in 15 min with 12 number of passes which shows the reduction in peaks and valleys with surface improvement of 71.79%.