Die Tool Steel Research Articles

Experimental Investigation on Axial Ultrasonic Vibration Assisted Milling of Cr12MoV

The conventional milling process is difficult due to the high strength and hardness of Cr12MoV, which can cause the rapid tool wear, premature failure,and poor milling quality of work platform. The ultrasonic vibration machining technology has been founded to be effective in the milling process of hard-to-cut materials like die tool steel and nickel alloys. The ultrasonic vibration assisted milling (UVM) technology is carried out the axial milling of Cr12MoV in this paper, and the average impact force Fi is influenced by the vibration amplitude A, the vibration frequency f, and equivalent mass of the vibrating part M. The mean value of cutting force Fx, Fy, and Fz decreases by 25%, 15.04%, and 17.46%, respectively. With the increase of vibration amplitudes, the value of surface roughness firstly decrease and then increase, and it is obviously lower than conventional milling. The experimental results demonstrated that the UVM technology is a feasible method for the low cutting force and high quality process of cutting Cr12MoV.

Comparison study on effect of different lubrication methods on tool wear and surface roughness during end milling of die tool steel

Among all the parameters of machinability evaluation, Surface roughness and chips are one the important parameters, which can influence the functionality and durability of the product machined. Previous research in the domain indicates that machining under dry and minimum quantity lubrication can be a sustainable alternative to the use of conventional flooded coolants. Also, it can minimize the negative impacts of chemical based flooded coolant on Environment, with satisfactory level of performance. This paper compares surface roughness and chips characteristics of Die tool steel material under Dry, Flooded and Micro Lubrication using uncoated carbide inserts. For attainable surface finish, quantification of contribution of input variables such as cutting speed, feed and lubrication mode, statistical method Analysis of Variance (ANOVA) is used. Surface roughness and Flank wear values under Micro-lubrication method significantly reduced compared to dry machining for machining length of 16,800 mm.

Performance evaluation of WEDM by application of MOGA

The phenomenon of spark erosion for forming complex profiles on conductive materials is applied in WEDM. In current research D3 die tool steel is assessed in terms of two conflicting responses i.e. surface roughness (Ra) and material removal rate (MRR). The critical parameters put into investigation are pulse on time (Ton), pulse off time (Toff), wire feed rate and peak current. For designing experiment sets obligatory to conduct test and output evaluation Taguchi L9 concept is applied using Minitab. ANOVA explains the contribution and significance for defined parameters and indicates that the significant parameters for MRR are Ton and wire feed while for Ra Toff is most significant followed by Ton.

Performance evaluation of cryogenically treated wires during wire electric discharge machining of AISI D3 die tool steel under different cutting environments

PurposeTool steel (AISI D3) is a preferred material for industrial usage. Some of the typical applications of D3 tool steel are blanking and forming dies, forming rolls, press tools and punches bushes. It is used under conditions where high resistance to wear or to abrasion is required and also for resistance to heavy pressure rather than to sudden shock is desirable. It is a high carbon and high chromium steel. Therefore, wire electric discharge machining (WEDM) is used to machine this tool steel. The paper aims to discuss these issues.Design/methodology/approachThe present experimental investigation evaluates the influence of cryogenically treated wires on material removal rate (MRR) and surface roughness (SR) for machining of AISI D3 steel using the WEDM process. Two important process responses MRR and SR have been studied as a function of four different control parameters, namely pulse width, time between two pulses, wire mechanical tension and wire feed rate.FindingsIt was found that pulse width was the most significant parameter which affects the MRR and SR. Better surface finish was obtained with cryogenically treated zinc coated wire than brass wire.Originality/valueThe review of the literature indicates that there is limited published work on the effect of machining parameters in WEDM in cryogenic treated wires. Therefore, in this research work, it was decided to evaluate the effect of cryogenically treated wires on WEDM.

Influence of Different Grades of CBN Inserts on Cutting Force and Surface Roughness of AISI H13 Die Tool Steel during Hard Turning Operation.

Now-a-days, the application of hard tuning with CBN tool has been massively increased because the hard turning is a good alternative to grinding process. However, there are some issues that need to be addressed related to the CBN grades and their particular applications in the area of hard turning process. This experimental study investigated the effects of three different grades of CBN insert on the cutting forces and surface roughness. The process of hard turning was made using the AISI H13 die tool steel at containing different hardness (45 HRC, 50 HRC and 55 HRC) levels. The work material were selected on the basis of its application in the die making industries in a range of hardness of 45–55 HRC. Optimization by the central composite design approach has been used for design and analysis. The present study reported that the cutting forces and surface roughness are influenced by the alloying elements and percentage of CBN in the cutting tool material. The work material hardness, feed rate and cutting speed are found to be statistically significant on the responses. Furthermore, a comparative performance between the three different grades of CBN inserts has been shown on the cutting forces and surface roughness at different workpiece hardness. To obtain the optimum parameters from multiple responses, desirability approach has been used. The novelty/robustness of the present study is represented by its great contribution to solve practical industrial application when is developed a new process using different CBN grades for hard turning and die makers of workpiece having the hardness between 45 and 55 HRC.

Optimization of Process Parameters of Abrasive Water Jet Machining (AWJM) on H13 Hot Die Tool Steel by Grey Relational Analysis

Optimization of Process Parameters of Abrasive Water Jet Machining (AWJM) on H13 Hot Die Tool Steel by Grey Relational Analysis

Effects of Process Parameters on Material Removal Rate and Surface Roughness in Wedm of H-13 Die Tool Steel

In research work variation of cutting performance with pulse on time, pulse off time, wire type, and peak current were experimentally investigated in wire electric discharge machining (WEDM) process. Soft brass wire and zinc coated diffused wire with 0.25 mm diameter and Die tool steel H-13 with 155 mm× 70 mm×14 mm dimensions were used as tool and work materials in the experiments. Surface roughness and material removal rate (MRR) were considered as performance output in this study. Taguchi method was used for designing the experiments and optimal combination of WEDM parameters for proper machining of Die tool steel (H-13) to achieve better surface finish and material removal rate. In addition the most significant cutting parameter is determined by using analysis of variance (ANOVA). Keywords Machining, Process Parameters, Material removal rate, Surface roughness, Taguchi method

Experimental Investigation on the Effects of Nano Fluid in ECM of High Carbon High Chromium Die Tool Steel

The formation of spikes in Electrochemical Machining (ECM) of High carbon high chromium die steel prevent to achieve the better Material removal rate (MRR) and surface finish using NaCl aqua electrolyte. Hence, this research work attempts to investigate the effects of Nano fluid i.e., Copper nano particles suspended Sodium Chloride (NaCl) aqua electrolyte on the Electrochemical Machining (ECM) of High carbon high chromium (HCHCr) die steel. The electrochemically machined work piece is one of the tremendously utilized materials in most of automotive industries despite of its poor machinability. The objective of this research is to minimize the formation of spikes using nano particle suspended electrolyte results higher MRR and lower surface finish. The selected influencing parameters are applied voltage, electrolyte discharge rate and tool feed rate with different levels. Seventy two experiments are conducted on HCHCr die steel using nano fluid. The results reveal that nano fluid significantly improves the MRR and surface finish than that of plain NaCl aqua electrolyte by 15.44% higher MRR and 41.49% lower surface roughness.

Machinability Study on Finish Turning of AISI H13 Hot Working Die Tool Steel With Cubic Boron Nitride (CBN) Cutting Tool Inserts Using Response Surface Methodology (RSM)

Finish turning of hardened die tool steel offers an economical alternative to grinding process. This study investigated the effects of machining parameters including workpiece hardness in a range of 45–55 HRC on cutting forces (F c & F t ), surface roughness (R a ) and cutting edge temperature (T) in finish turning of AISIH13 die tool steel with CBN inserts. Workpiece material AISIH13 has been selected on the basis of its wide applications in die making industries in the range of hardness 45–60 HRC. A central composite design has been used for the design of experimentation, and by using response surface methodology, a mathematical model has been developed. This study reported that the cutting forces are primarily influenced by the hardness of workpiece material. The work material hardness, feed rate and depth of cut are also statistically significant on cutting forces. Also, cutting forces increases, with the increase in workpiece hardness, feed and depth of cut, whereas the cutting speed has least impact on cutting forces. In fact, increase in hardness of work material resulted in better surface roughness as well as increase in tool tip temperature. Furthermore, optimum parameters are obtained through multi-response optimization technique using desirability function approach. The novelty aspect of the present study is that it contributes to practical industrial application of finish turning for the die and mold makers to select the optimum cutting conditions in a range of hardness of 45–55 HRC.

Optimization of Processing Parameters in ECM of Die Tool Steel Using Nanofluid by Multiobjective Genetic Algorithm.

Formation of spikes prevents achievement of the better material removal rate (MRR) and surface finish while using plain NaNO3 aqueous electrolyte in electrochemical machining (ECM) of die tool steel. Hence this research work attempts to minimize the formation of spikes in the selected workpiece of high carbon high chromium die tool steel using copper nanoparticles suspended in NaNO3 aqueous electrolyte, that is, nanofluid. The selected influencing parameters are applied voltage and electrolyte discharge rate with three levels and tool feed rate with four levels. Thirty-six experiments were designed using Design Expert 7.0 software and optimization was done using multiobjective genetic algorithm (MOGA). This tool identified the best possible combination for achieving the better MRR and surface roughness. The results reveal that voltage of 18 V, tool feed rate of 0.54 mm/min, and nanofluid discharge rate of 12 lit/min would be the optimum values in ECM of HCHCr die tool steel. For checking the optimality obtained from the MOGA in MATLAB software, the maximum MRR of 375.78277 mm3/min and respective surface roughness Ra of 2.339779 μm were predicted at applied voltage of 17.688986 V, tool feed rate of 0.5399705 mm/min, and nanofluid discharge rate of 11.998816 lit/min. Confirmatory tests showed that the actual performance at the optimum conditions was 361.214 mm3/min and 2.41 μm; the deviation from the predicted performance is less than 4% which proves the composite desirability of the developed models.

Experimental Investigation of Surface Finish and Material Removal Rate of P20 Die-Tool Steel in Wire-EDM using Multiple Regression Analysis

Experimental Investigation of Surface Finish and Material Removal Rate of P20 Die-Tool Steel in Wire-EDM using Multiple Regression Analysis