In permanent molds, surface finishing is an essential parameter for defining the esthetic features of the product manufactured using them. For obtaining the required surface roughness, various processes are developed in order to reduce the human effort as well as time. In the present work, an effort has been made to optimize the process parameters for nano-surface finishing of hardened AISI 52100 steel that (material) is excessively used in industries for manufacturing of permanent molds. The hardened AISI 52100 steel surfaces have been finished using a magnetorheological solid core rotating tool. The material on which the present finishing process is performed has a hardness of 50 ± 2 HRC which matches the industrial standards of hardness for manufacturing of permanent molds. Response surface methodology is used for the parametric analysis of the magnetorheological fluid-based nanofinishing process. The effects of variation in process parameters on the percentage change in average surface roughness of hardened AISI 52100 steel are analyzed and optimized. The study of change in surface morphology is also analyzed using scanning electron microscopy. Surface cracks formed due to traditional finishing process are eliminated using the present solid rotating core magnetorheological finishing process. The finishing process applied with optimized parameters has been able to finish the workpiece surface up to 20 nm which matches the industrial SPI-A1 finishing standard with 20 min reduction in finishing cycle time.
The International Journal of Advanced Manufacturing Technology – Springer Journals
Published: Oct 27, 2017
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