Statistical approach to optimize the process parameters of HAZ of tool steel EN X32CrMov12-28 after die-sinking EDM with SF-Cu electrode

Abstract

The paper describes the results of the experimental research of the heat affected zone (HAZ) of an eroded surface after die-sinking electrical discharge machining (EDM). The research was carried out on chrome-molybdenum-vanadium alloyed tool steel EN X32CrMoV12-28 (W.-Nr. 1.2365) after die-sinking EDM with a SF-Cu electrode. The aim of the experimental measurements was to contribute to the database of knowledge that characterizes the significant impact of the main technological and process parameters on the eroded surface properties during die-sinking EDM. The quality of the eroded surface was assessed from the viewpoint of surface roughness, microhardness variation, and the total HAZ depth of the thin sub-surface layer adjacent to the eroded surface. On the basis of measurement results, mathematical models were established by statistical methods. These models can be applied for computer simulation and prediction of the resultant quality of the machined surface after die-sinking EDM. The results achieved by simulation were compared with the results of experimental measurements and high correlation indexes between the predicted and real values were achieved. Suggested mathematical models can be also applied for the determination of the optimal combination of significant technological parameters in order to minimize microhardness and total HAZ depth variations of tool steel EN X32CrMoV12-28 after die-sinking EDM with a SF-Cu electrode.