Investigation of Parameters Affecting Surface Integrity and Material Removal during Electrical Discharge Machining of HARDOX-400 Steel

محورهای موضوعی : Conventional/Non-Conventional Machining

Hesam Motevasseli ¹ (M.Sc., Department of Mechanical Engineering, School of Engineering, Shiraz Branch, Islamic Azad University, Box 71993-1, Shiraz, Iran)
Ahmad Afsari ² (Associate Professor, Department of Mechanical Engineering, School of Engineering, Shiraz Branch, Islamic Azad University, Box 71993-1, Shiraz, Iran)
Ali Khosravifard ³ (Assistant Professor, Metallurgical and Materials Engineering Department, School of Engineering, Shiraz Branch, Islamic Azad University, Box 71993-1, Shiraz, Iran)

تاریخ دریافت : 1399/01/24 تاریخ پذیرش : 1399/04/30 تاریخ انتشار : 1399/02/12

کلید واژه: Roughness, Hardox, Discharge Machining, Surface Integrity, Pulse Time,

چکیده مقاله :

Hardox-400 with an extra-high yield strength of ~1000 MPa and excellent abrasion resistance is a good candidate for several industrial applications including automotive parts, working tools, barges, loaders, etc. Due to high dimensional precision and to avoid mechanical abrasion of the work-piece, electrical discharge machining (EDM) is a proper machining technique for such steel. The influences of important process parameters, i.e. discharge current and spark pulse cycle on the electrode wear, material removal, surface roughness, and integrity of the machined material is investigated. It was observed in this work that as the discharge current increased, the electrode wear also increased but this occurred with a gradually decreasing rate. On the other hand, increasing the ratio of pulse-on to pulse-off time decreased material removal. Furthermore, it was observed that increasing both the discharge current and the pulse-on time led to a thicker solidified so-called white layer which is more susceptible to cracking and thus is detrimental to the material integrity.

منابع و مأخذ:

[1] Neimitz, A. 2014. Ductile fracture mechanisms in the high-strength steel Hardox-400, Microscopic observations and numerical stress-strain analysis. Procedia Materials Science. 3: 270 – 275.

[2] Frydman, S., Konat. L. and Pekalski. G. 2008. Structure and hardness changes in welded joints of Hardox steels. Archives of Civil and Mechanical Engineering. 8: 15-27.

[3] Naik, D.K. and Maity, K.P. 2018. An optimization and experimental analysis of plasma arc cutting of Hardox-400 using Taguchi based desirability analysis. MaterialsToday: Proceedings. 5: 13157-13165.

[4] Ulewicz, R. and Nový, F. 2017. Fatigue resistance and influence of cutting technology on the mechanical properties of modern steels used in the automotive industry. Procedia Engineering.  192: 899-904.

[5] Dahil, L., Dahil, I. and Karabulut, A. 2014. Comparison of advanced cutting techniques on hardox 500 steel material and the effect of structural properties of the material. Metalurgija. 53: 291-294.

[6] Chamarthi, S., Reddy, N.S. Elipey, M.K. and Reddy, D.V.R. 2013. Investigation Analysis of Plasma arc cutting Parameters on the Unevenness surface of Hardox-400 material. Procedia Engineering. 64: 854 – 861.

[7] Prajapati, B.D., Patel, R.J. and Khatri, B.C. 2013. Parametric Investigation of CO₂ Laser Cutting of Mild Steel and Hardox-400 Material. International Journal of Emerging Technology and Advanced Engineering. 3: 204-208.

[8] Hashemzadeh, M. and Mahammadi, M. 2020. The Effect of Power and Maximum Cutting Speed on the Material Removal Rate and Cutting Volume Efficiency in CO₂ Laser Cutting of Polycarbonate Sheets. Journal of modern processes in Manufacturing and production. 9: 5-23.

[9] Tosun, N., Cogunb, C. and Tosun, G. 2004. A study on kerf and material removal rate in wire electrical discharge machining based on Taguchi method. Journal of Materials Processing Technology. 152: 316-322.

[10] Uhlmann, E., Piltz. S. and Doll, U. 2005. Machining of micro/miniature dies and moulds by electrical discharge machining-Recent development. Journal of Materials Processing Technology. 167: 488-493.

[11] Bai, X., Zhang, Q., Zhang, J., Kong, D. and Yang, T. 2013. Machining efficiency of powder mixed near dry electrical discharge machining based on different material combinations of tool electrode and workpiece electrode. Journal of Manufacturing Processes. 15: 474-482.

[12] Zhang, Q.H., Dub, R., Zhang, J.H. and Zhang, Q.B. 2006. An investigation of ultrasonic-assisted electrical discharge machining in gas. International Journal of Machine Tools and Manufacture. 46: 1582-1588.

[13] Ming, W., Zhang, Z., Wang, S., Zhang, Y., Shen, F. and Zhang, G. 2019. Comparative study of energy efficiency and environmental impact in magnetic field assisted and conventional electrical discharge machining. Journal of Cleaner Production. 214: 12-28.

[14] Wu, K.L., Yan B.H, Lee., G.W. and Ding, C.G. 2009. Study on the characteristics of electrical discharge machining using dielectric with surfactant. Journal of Materials Processing Technology. 209: 3783-3789.

[15] Che Haron, C.H., Ghani, J.H., Burhanuddin, Y., Seong, Y.K. and Swee, C.Y. 2008. Copper and graphite electrodes performance in electrical-discharge machining of XW42 tool steel. Journal of Materials Processing Technology. 201: 570-573.

[16] Younis, M.A., Abbas, M.S., Gouda, M.A., Mahmoud, F.H. and Abd Allah, S.A. 2015. Effect of electrode material on electrical discharge machining of tool steel surface. Ain Shams Engineering Journal. 6: 977-986.

[17] Ghrib, T., Salem, S.B. and Noureddine, Y. 2009. EDM effects on the thermal properties of 36NiCrMo16 steel. Tribology International. 42: 391-396.

[18] Cao, C., Zhang, X., Zha, X. and Dong, C. 2014. Surface integrity of tool steels multi-cut by wire electrical discharge machining. Procedia Engineering. 81: 1945-1951.

[19] Chamarthi, S., Reddy, N.S., Elipey, M.K. and Reddy, D.V.R. 2013. Investigation Analysis of Plasma Arc Cutting Parameters on the Unevenness Surface of Hardox-400 Material. Procedia Engineering. 64: 854-861.

[20] Bobbili, R., Madhu, V. and Gogia, A. K. 2015. Modelling and analysis of material removal rate and surface roughness in wire-cut EDM of armour materials. Engineering Science and Technology an International Journal. 18: 664-668.

[21] Guu, Y. H., Hocheng, H., Chou, C.Y., Deng, C.S. 2003. Effect of electrical discharge machining on surface characteristics and machining damage of AISI D2 tool steel. Materials Science and Engineering A. 358: 37-43.

[22] Muthuramalingama, T. and Mohan, B. 2014. Application of Taguchi-grey multi responses optimization on process parameters in electro erosion. Measurement. 58: 495-502.

[23] Azimi, M., Kolahdooz, A. and Eftekhari, S. A. 2017. An Optimization on the DIN1.2080 Alloy in the Electrical Discharge Machining Process Using ANN and GA. Journal of modern processes in manufacturing and production. 6: 33-47.

[24] Mohammed Azarudeen, J., Kaja Bantha Navas, R., Vikas Reddy, G., Gowsik Saran, R. S., Prakash, S. and Anderson, A. 2020. Optimizing the process parameters for Powder metallurgy electrode inElectrical Discharge Machining. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2020.02.920.

[25] Muthuramalingam, T., Mohan, B. and Jothilingam, A. 2014. Effect of Tool Electrode Resolidification on Surface Hardness in Electrical Discharge Machining. Materials and Manufacturing Processes. 29: 1374-1380.