HSS M2 Research Articles

Corrosion study of CA-PVD coated perforation cutter blades of different metallurgies used for liquid shampoo packaging

Perforation cutters must tackle aggressive corrosion and wear while filling sachets/pouches containing shampoo liquids and conditioners. The present work aims to enhance the durability of the perforation cutters through the application of PVD coatings. Further, this study investigates the role of surface energy and wettability to understand the corrosion behavior of different cutter metallurgies (SS420, D2, and HSS M2) and different coatings in shampoo liquids and conditioners. Two PVD coatings, namely Titanium Nitride (TiN) and Chromium Nitride (CrN), were chosen for this work. The most popular FMCG hair shampoo and conditioner combination in South Asia was selected for the study. The coated cutters were exposed to 20% concentration by volume of different shampoo solutions and their corrosion rates were compared with uncoated cutters. The CrN-coated SS420 specimen exhibited the most significant improvement in corrosion resistance with low wettability compared to all other specimens tested in various solutions. In contrast, the uncoated M2 specimen suffered the most severe corrosion with high wettability in various solutions. An inverse correlation was observed between wettability and corrosion resistance for the various specimens. The findings of this study give a better understanding of the corrosion of perforation cutters by shampoo liquids, elucidating the impact on their longevity and providing insights into the potential benefits of PVD coatings for enhancing their durability.

Study of the effect of asymmetric rolling followed by ion nitriding on the hardness and structure of HSS M2 tool steel

Study of the effect of asymmetric rolling followed by ion nitriding on the hardness and structure of HSS M2 tool steel

Investigation of influence of ion nitriding in the glow discharge with magnetic field on microstructure and microhardness of steel HSS M2 with preliminary plastic deformation

This work was devoted to the study of the influence of magnetic field on microhardness of HSS M2steel during ion nitriding in the glow discharge. The samples were preliminarily subjected to intenseplastic torsion deformation (IPTD). Standard methods of optical metallography and microhardnessmeasurements were used in the experiments. It was found that IPTD allows creating ultrafine-grained(UFG) structure in the material, and magnetic field allows intensifying the process of ion nitriding byincreasing the number of ionization acts, which leads to an increase in the thickness of the diffusionlayer and microhardness compared to ion nitriding without preliminary IPTD and without magneticfield. The results obtained indicate the importance of using a magnetic field during ion nitridingin the glow discharge. The described effects are of potential interest for improving the mechanicalproperties of high-speed steels.

Исследование микротвердости и структуры инструментальных сталей после ионно-плазменного азотирования в тлеющем разряде

In this paper, the effect of ion-plasma nitriding (IPA) on the microhardness and structure of tool steels is investigated. Samples of HSS M2 and P18 steels, quenched at 1300°Cand then tempered three times at 550°C, were used for the study. The IPA was carried out in a gas mixture consisting of 50% argon, 35% nitrogen and 15% hydrogen at a pressure of 250 Pa and a surface temperature of 400°C, 500°C and 600°C for 3h, 6h and 9h, 9 h. It was found that the highest surface hardness of 1600 HV for HSS M2 steel specimens and 1500 HV for P18 steel specimens were observed after IPA in TR at 500°Cfor 9 h. The maximum hardened layer depth of 120 μm for HSS M2 specimen and 100 μm for P18 specimen were observed after treatment at the same temperature for 6 and 9 hours

Grain size, carbide distribution and hardness issues pertaining to cutting tools produced from high speed steel scraps

ABSTRACT Single point cutting tool blanks are prepared adopting the centrifugal casting method using only scrapped high-speed steel tools collected from different installations for better mechanical properties and economical production. The cast cylindrical blanks are cut into shapes by wire-cut EDM and subsequently heat-treated. Upon heat treatment, the centrifugal cast tool exhibited a reduction of grain size about 60% accompanied by about 22.7% increase in the hardness. The conventional cast HSS M2 tools procured from the market are compared with centrifugal cast tools. SEM images of both tools showed two different eutectic carbide patterns. Also, the precipitation of M6C and MC carbides are found in XRD analysis for both tools. Upon EDX analysis, W, V, and Cr are found to be the prime elements responsible for carbide formation. Wear characteristics of centrifugal cast tool observed are as par with the HSS M2 tool during turning of mild steel (ASTM A36) under identical environment. This method will be helpful for the development of cutting tools for industrial applications.

Si-DLC films deposited by a novel method equipped with a co-potential auxiliary cathode for anti-corrosion and anti-wear application

A novel DLC film deposition method was proposed to realize the deposition of DLC film on the surface of complex shaped workpiece. Meanwhile, Si-DLC film was deposited on the surface of M2 high-speed steel (HSS M2) and 304 stainless steel (304SS), and the microstructure, surface roughness, mechanical properties, corrosion resistance and tribological properties of Si-DLC films were characterized in detail. Results show that Si-DLC film at different axial positions of the auxiliary cathode possesses similar microstructure, film thickness and surface roughness, and the as-deposited Si-DLC film shows the low intrinsic stress of < 0.3 GPa. Compared with the 304SS substrate, the Si-DLC film presents more noble corrosion potential, lower corrosion current density and higher polarization resistance, exhibiting higher corrosion resistance. Moreover, the Si-DLC film exhibits higher hardness, elastic factor and plastic factor than HSS M2 substrate and the corresponding adhesive strength is more than 10 N. The Si-DLC film sliding against GCr15 steel ball shows a lower friction coefficient than that of HSS M2 substrate and the wear rate of GCr15 steel ball sliding against the Si-DLC is lower than that of HSS M2 substrate. In addition, this novel method was used to deposit Si-DLC film on gears, drills and bearings without rotating sample racks. As a consequence, this method possesses great potential and can be generalized for the deposition of DLC film on the surface of complex shape workpiece.

Performance analysis of cryoprocessed conventional HSS M2 drill and P/M HSS M3 TiN coated tap and its effect on the substructure

The experimental study investigates the performance of cryogenically treated conventional uncoated H.S.S. M2 Drills and P/M H.S.S. M3 TiN coated taps. The fermentation factors and their assigned values maintained constant throughout the study were soaking temperature of −185 °C, soaking time of 16 h, cooling rate 1 °C/min to 2.5 °C/min followed by soft tempering at temperature 100 °C and soft tempering time of 1 h. For conventional uncoated H.S.S. M2 drills, the speed and feed rate were offset by 10% on lower side and higher side of the datum. For P/M H.S.S. M3 TiN coated taps, the speed and feed rate were offset by 5 % in the steps of three on the higher side of datum. It has been observed that tool life of conventional uncoated H.S.S. M2 Drills is improved by 100% or twice with 10 % increase in speed and by 80 % or 1.6 times with 10 % increase in feed rate. The tool life of P/M H.S.S. M3 TiN coated taps increased by 175 % or 3.44 times with 10 % increase in speed and feed rate as compared to the datum parameters. TiN coated taps shows maximum tool life without any damages or dislodgement to the coated surface. Therefore the adherence of coating is found to be strong without any interfacial imperfection between the matrix and the coating. The increased tool life of such coated tools can be attributed to decreased surface roughness values. The improved performance of the drills can be attributed to refinement in carbides which increases wear resistance during cutting.

The effect of counterbody on tribological adaptation of an electron beam deposited HSS M2 steel coating in a range of sliding speeds and normal loads

A relationship between wear behavior and structural-phase state of HSS M2 electron beam cladded coating rubbed against AISI52100 or AISIO7 counterbodies in a range of loads and speeds has been established. When rubbing the coating against the AISIO7 counterbody the wear rate increased with the normal load while coefficient of friction decreased. The effect of the counterbody on wear and friction higher speeds was related to generation of mechanically mixed layers (MMLs) composed of iron tungstate, carbide fragments and transferred metal. Steady wear rate vs. time dependence in M2/AISI O7 pair is due to higher amount of this mixed oxide.

Minimization of thrust force and surface roughness during MQL coolant drilling on tool steel using BPNN-ACO

The excessive thrust force that generated during the minimum quantity lubrication (MQL) drilling process of tool steel can lower the hole surface quality. Hence, it is necessary to properly choose the combination of machining variables to minimize thrust force (TF) and hole surface roughness (HSR) simultaneously. This study underlines the modelling and minimizing the thrust force and hole surface roughness developed during MQL drilling process by integrating a backpropagation neural network (BPNN) method and ant colony optimization (ACO). The varied drilling parameters were type of drill bit, drill point angle, feeding speed, and cutting speed. The optimum BPNN architecture could be obtained by using 4-20-2 network architecture with tansig activation function. The optimum MQL drilling parameters that can minimize TF and HSR simultaneously were HSS M2 drill bit, 107° of drill point angle, 0.045 mm/rev of feeding speed and 36 m/min of cutting speed.

Study of cutting ability of centrifugal cast HSS cutting tool in optimized process parameters

The purpose of the investigation is to propose an innovative method of single point cutting tool development adopting centrifugal casting operations. Scrapped cutting tools are melted, cast into cylindrical bars adopting centrifugal casting method, machined for developing single point cutting tools, and heat-treated for the conduct of cutting operations. Adopting Taguchi optimisation technique and considering the-smaller-the better approach, optimisation of cutting parameters viz, cutting velocity, depth of cut and feed rate for minimum surface roughness and cutting force are attempted during dry turning of mild steel (A36). Evaluation of the effect of cutting parameters on the output such as the surface roughness and the cutting force is done by using ANOVA software. The above mention studies are also repeated with the HSS cutting tool available in the market (HSS M2). The cutting ability of both tools on the basis of cutting parameters, as mentioned above is found to be at par. Also, analysis of wear characteristics yielded almost similar results. The study verifies the centrifugal casting method as a viable method for the development of single point cutting tools using scrapped tools.

Tribological behaviour of uncoated steel and fluorocarbon coated steel under dry and lubricated sliding conditions

Due to positive tribological performance, fluorocarbon coatings have established an importance in many applications, as a possible replacement to enhancement and substitute traditional liquid lubricants. The literature in this area is to a certain extent limited, especially on the Tribological behaviour of fluorocarbon coated and fluorocarbon uncoated components in aggressive conditions. In this work, fluorocarbon coated on HSS M2 and fluorocarbon uncoated components friction and wear along with this it also gives smooth and noise free running operation. Long-term durability experiments also showed the superiority and suitability of fluorocarbon coating for potential use in many applications. Fluorocarbon coatings are considered for their advantageous mixture of properties, in specific it has exceptional low friction as well as release capability and good chemical properties. As a result of experimentations, fluorocarbon coating shows the coefficient of friction as low as 0.196 which is much better than many other coatings in the fluorocarbon category and wear rate is also way better which is 1.0610×10-5mm3/Nm.

Effect of ion bombardment and micro-blasting on the wear resistance properties of hard TiN coatings

Ion bombardment (IB) is conventionally used as a pre-coating treatment process to increase surface energy of tools to improve the adhesion of coatings produced using cathodic arc Physical Vapour Deposition (CA-PVD) technique. Micro-blasting (MB) as a post-treatment process is used to improve the surface finish of the coated tools. Both these processes impact surface finish, adhesion and wear resistance of the coated tools. This article presents a systematic study to understand the effects of these two processes on the surface finish, adhesion and wear resistance properties of TiN coated HSS substrate. IB process was carried out using Ti ions for different time periods which results in the formation of Ti layer on HSS M2 grade substrate. This was followed by TiN coating deposited at −150 V bias voltage and 1.3 Pa of nitrogen gas. Coating properties evaluated were: coating micro-structure, surface morphology, surface roughness, macroparticle (droplet) density, adhesion and wear rate. TiN coating with FCC structure was confirmed using XRD measurements. With the decrease in IB time from 25 min to 5 min, the surface roughness reduces from 0.31 µm to 0.15 µm respectively. Adhesion and Calo wear tests also showed improvement in adhesion and wear resistance with the reduction in IB time. The TiN coated sample without IB process was also prepared, which exhibited lowest surface roughness and droplet density, but the coating adhesion and wear resistance properties were optimum for 5 min IB treated HSS. The Ti layer deposited during the IB process helps in improving the coating adhesion. However, as the result shows, higher Ti inter-layer thickness results in poor adhesion and higher roughness. Thus, to get better wear resistance and adhesion, ion bombardment is necessary but has to be kept as low as possible. In addition, Post-coating MB process was carried out at different pressures and time on TiN coated sample to identify the optimum pressure and time which improves wear resistance of the coating.

Vibration Signal Responses Classification in AA 6063 Aluminum Alloy Friction Stir Welded joint Using Optimal Neural Network

Friction-stir-welding (FSW) is a firm stipulation dual procedure and its possessions are reliant on the welding procedure confines. Investigational results are executed by an advance speed revolving apparatus negotiating AA 6063 aluminium alloy 4 mm width laminate substance by FSW apparatus which is formed by HSS M2 substance. The DWT is utilised to decay the vibration signal in different welded dual. Following the signal decay procedure, the signals are indicated to categorisation procedure. Arithmetical and chronological limits of decay vibration signals by wavelet transform have been employed as the input of the FFBN. For improving the classification performance optimises the network structure hidden the layer and hidden neuron optimisation techniques are used. The optimal hidden layer and neuron attained in OGA technique to organise the vibration signals. This experimental and simulation analysis proves that vibration signal analysis method could be used to concern in process condition monitoring in friction stir welding process.

English

The disc brake is a device used for slowing or stopping the rotation of the vehicle. Number of times using the brake for vehicle leads to heat generation during braking event, such that disc brake undergoes breakage due to high stress. The transient stress and structural analysis is preferred to choose the low stress material for better performance. Disc brake model is done by CATIA and analysis is done by using ANSYS workbench. The main purpose of this project is to study the analysis of the stress for the Aluminium, Grey Cast Iron, HSS M42, and HSS M2. The stress and structural analysis is performed for four materials and the stress is established in the disc for different materials. A comparison between the four materials for the stress values and material properties obtained from the stress analysis and structural analysis low stress material is preferred. Hence best suitable design, low stress material Aluminium is preferred for the Disc Brakes for better performance.

Evalution of Surface Finish on Machining Of Mild Steel Using High Speed Steel Tool in Lathe with Normal Coolant (Or) Nano Material Added Coolant

Surface finish is one of the prime requirements of industrial machining. The purpose of this project is focused on the analysis of optimum cutting conditions to get lowest surface roughness in turning. This paper presents an experimental study to investigate the effects of cutting parameters like spindle speed, feed, depth of cut and nano material added type of coolant on surface finish on EN-8 by HSS M2 tool. The objective was to establish correlation between cutting speed, feed rate, depth of cut and type of coolant to optimize the turning conditions based on surface roughness. The study was conducted through RSM method with the help of Design Expert 8.0 software. We have used Servo cut of Indian oil or cool edge SL of Castrol used with water in a ratio of 1:20 as per manufacturer specification. The experiment conducted with 3 different speed, feed and DOC with out nano material ordinary coolant and with one nano material (TiO2) included coolant for L27 method.

Influence of adhesion between coating and substrate on the performance of coated HSS twist drills

This work analyses the performance of the TiN/TiCN, TiAlN, TiN/TiAlN and TiN/TiAlN/WCC coatings on HSS M2 drills used in the drilling of the aluminium-silicon alloy ISO 3522 AlSi8Cu3Fe, correlating the life of the tools to the coating adhesion characterization experiments. Coating adhesion was characterized using Rockwell C indentation tests and scratch tests with progressive load. The performance of the coatings in the life experiments was the following, in decreasing order: TiN/TiCN, TiAlN, TiN/TiAlN/WCC and TiN/TiAlN. In the adhesion characterization experiments with TiN/TiCN there were no cracks or delamination of the coatings, which justifies its best performance in the life experiments.

Aplicação de brocas de aço-rápido na usinagem

Actually, machining without cutting fluid is one of the most discussed topics of the metal-mechanical industry. The high cost of fluids, ecological problems in the work environment and the destination of wastes, as well the health of workers, have encouraged the removal or restriction of the use of cutting fluids. The research of the drilling process seeks to adapt cutting conditions and circumstances to perform machining without cutting fluid. Thus, this paper reports a study of the lack’s effects of cutting fluids in high-speed-steel tools HSS M2, in machining of steel AISI P20. For the development of tests were used twist drills DIN 338, with two edges, uncoated. The drills had mainly the mechanisms of abrasion and adhesion. The absence of the cutting fluid became the process quite severe, subjecting the tools to high thermal solicitations. Key words: drilling, dry machining, wear mechanisms.

Analytical correlation of hardness and scratch adhesion for hard films

An analytical expression has been derived in order to correlate the critical load of scratch adhesion L c with hardness and film thickness for thin hard films on softer substrates, based on the model proposed by Burnett, Rickerby and co-workers (B–R model) for interpretation of composite hardness measurements. The equation was used to calculate the correlation of L c with H v(sub) (substrate Vickers hardness), H v(comp) (composite Vickers hardness), and t (film thickness) for AISI 316 stainless steel, HSS M2 and WC substrates coated with TiN films of different thickness. The calculated results were compared with experimental data for TiN films produced under similar conditions by PACVD and PAPVD deposition techniques. The present analysis yields quantitative results which agree to a satisfactory degree with experimental data in all cases considered and contribute to the understanding of the physical processes which control the deformation of the film–substrate mechanical system under scratch indentation conditions.

Optimization of vacuum heat treatment of cutting dies made from HSS M2 (AISI)

The manufacturing of cutting dies from HSS M2 (AISI) is one of the most important vacuum heat treatment operations with uniform high-pressure gas quenching. The importance of optimal heat treatment, is the possibility of making the optimal combination of the basic characteristics of cutting dies made from HSS for the given working par/cutting die combination. Three different austenitization temperatures, and five different tempering temperatures were chosen. Some of the cutting dies were cold treated and coated with TiN by PVD, to produce the correct hardness balance, toughness, cutting properties and wear resistance in the finished tool. The result of the present investigation is important for the optimization of the vacuum heat treatment of different tools made from HSS which are under tensile impact stress during exploitation. For them, optimal combination of hardness and fracture toughness are decisive.

Life of Tin and Ti(C,N) Coated and Uncoated HSS Drills

TiN and Ti(C,N) coatings have been applied to 156 in (7.94 mm) dia. HSS M2 drills for use on mild steel workpieces. Reactive ion plating utilising an evaporation source was used to produce coating layers 1j1m in thickness. Axial and radial vibration signals were recorded for coated and uncoated HSS drills and subjected to high resolution signal analysis. A lubricant was used and speed and feed were kept constant at 50 m min-1 and 375 mm min-1 respectively throughout. Tool wear was measured on the flank of the drills by means of a television projector. Worn drills were also examined by SEM to determine the failure mode. Surface roughness of the drilled holes was examined for both coated and uncoated tools. Coated tools had longer lives as a result of lower wear rates and smaller built up edges as well as the lower thermal conductivity of the coating.