Characterization and Parametric Evaluation of Wire Electrical Discharge Machining of Cold Work Tool Steels

• Main Author: Abdul Rahim, Mohd Aidil Shah
• Format: Thesis
• Language: English; English
• Published: 2019
• Subjects: T Technology (General); TJ Mechanical engineering and machinery
• Online Access: http://eprints.utem.edu.my/id/eprint/25534/1/Characterization%20and%20Parametric%20Evaluation%20of%20Wire%20Electrical%20Discharge%20Machining%20of%20Cold%20Work%20Tool%20Steels.pdf; http://eprints.utem.edu.my/id/eprint/25534/2/Characterization%20and%20Parametric%20Evaluation%20of%20Wire%20Electrical%20Discharge%20Machining%20of%20Cold%20Work%20Tool%20Steels.pdf; http://eprints.utem.edu.my/id/eprint/25534/; https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=119781
• Institution: Universiti Teknikal Malaysia Melaka

XW42 is a cold work tool steels which is suitable for mould and die application. It has been proven to have an impair value of hardness and toughness which need to be improved. This research provides finding on Ml and M3 which provide an increase in its bulk hardness from 51.5HRC to 52HRC (Ml) and 52.6HRC (M3) and its impact toughness from 6.84J to 5.78J (Ml) and 8J (M3). Precipitation of hard carbides such as Cr23C6, Cr7C3, CrC and V2C are the cause for high hardness and segregation of eutectic carbide network cause for high toughness. M2 with lower bulk hardness at 49.8HRC and lower toughness at 5.03J due to low carbon content. Micro-hardness value for XW42, Ml, M2 and M3 were 614HV, 613.7HV, 613.4HV and 6171-1V. M3 keen to have the smallest grain size at 63.4um followed with Ml (644m), XW42 (65.3um) and M2 (66.7um). The combined effects of the machine factors on three machine responses were investigated by employing two levels of full factorial design (FFD) and analysis of variance (ANOVA). The results showed that material removal rate (MRR) was strongly influenced by the interaction of Ton/V and V/WT while surface roughness (SR) was dominantly controlled by Ton, and white layer thickness (WLT) was strongly controlled by V. Machinability through wire electrical discharge machining (WEDM) revealed that M3 could produce the lowest WLT at 144.32um at Ton: 2gs, V: IOV, WT: 120N meanwhile the highest MRR resulted with the lowest at SR 1.92gm are produced at Ton: 2gs, V: 6V; WT: 120N. An average error values of 8.67%, 0.7% and 8.2% between measured and predicted values of MRR, SR and WLT provides guidance for high skill machinery in completing quality end product. M3, with and machinability, it is keen to undergo the process of cutting, within the thickness up to 12mm.