Surface morphology evaluation of hardened HSLA steel using cryogenic-treated brass wire in WEDM process

• Published in: International journal of advanced manufacturing technology Vol. 104; no. 9-12; pp. 4445 - 4455
• Main Authors: Tahir, Waseem, Jahanzaib, Mirza, Ahmad, Wasim, Hussain, Salman
• Format: Journal Article
• Language: English
• Published: London Springer London 01.10.2019; Springer Nature B.V
• Subjects: Adequacy; Brasses; CAE) and Design; Cold treatment; Computer-Aided Engineering (CAD; Cryogenic treatment; Deionization; Electric discharge machining; Engineering; Fractional factorial design; High strength low alloy steels; Industrial and Production Engineering; Mechanical Engineering; Media Management; Microhardness; Morphology; Original Article; Process parameters; Thickness; Variance analysis; Wire; Workpieces; Recast layer thickness; HSLA; Cold-treated brass wire; Surface morphology; Wire material infusion; Micro-hardness; Fractional factorial design
• DOI: 10.1007/s00170-019-04301-0
• ISSN: 0268-3768

Surface morphology of a high strength low alloy steel is analyzed on wire electric discharge machining (WEDM) process with a cold-treated (CT) brass wire. Cold treatment process is carried out at − 70 °C for 24 h to refine the microstructure of brass wire for smooth discharge energy during machining process. Fractional factorial design is used to measure the response of recast layer thickness (RLT), wire material infusion (WMI), and micro-hardness (MH) of hardened HSLA steel. CT brass wire, servo voltage (SV), pulse on time ( T on ), pulse off time ( T off ), wire tension ( T w ), and flushing pressure ( F p ) of deionized water are selected as input process parameters. Analysis of variance (ANOVA) is performed to test the adequacy and significance of the developed mathematical models. T on is observed as the most effective input process parameter followed by T off and CT brass wire. Low-energy parameters with CT brass wire exhibits results with reduced RLT and WMI on machined surface as compared to NCT brass wire. CT brass wire is less wear off with respect to NCT brass wire while machining workpiece at same input process parameters.