Experimental Study of the Effects of the Ultrasonic Peening Treatment on Surface Hardness and Hardness Depth of Wire EDMed Workpieces

Document Type : Research Paper

Authors

Department of Manufacturing, Faculty of Mechanical Engineering, University of Kashan, Kashan, Iran

10.22099/ijmf.2024.49938.1290

Abstract

Wire EDM is a modern machining process that uses electrical discharge to cut workpieces. High temperatures generated by wire EDM can cause surface cracking due to metallurgical changes. A new approach is to use the ultrasonic peening treatment to cause surface severe plastic deformation to improve the mechanical properties, especially the hardness. In this study, the focus was on exploring the impact of cutting types in wire EDM, feeding rate, and the number of peening passes as input parameters on Mo40 (1.7225) alloy steel. The experiments were designed using the multilevel factorial design method. The average hardness values were then analyzed based on the input parameters. The maximum hardness value was determined through optimization using the multilevel factorial design method. Analysis of variance was used to evaluate the impact of parameters on hardness. The highest hardness value of 952.7 (HV) was obtained with a feeding rate of 0.12 (mm/rev) and 3 peening passes in roughing mode, leading to a 48% increase in hardness. A mathematical model with 99.87% desirability was developed to study the correlation between input parameters and response variables. The hardness distribution in the peened workpieces continued up to 200 µm below the surface layers. The highest hardness was found at a feeding rate of 0.12 (mm/rev), which influences the time needed to alter dislocation density and form a new sublayer structure. Overall, increasing the feeding rate decreases hardness, while increasing peening passes increases it. According to a single-objective optimization, the cutting types, feeding rate, and number of peening passes respectively affect hardness value.

Keywords

References

 [1]  Ekmekci, B. (2009). White layer composition, heat treatment, and crack formation in electric discharge machining process. Metallurgical and Materials Transactions B, 40, 70-81. https://doi.org/10.1007/s11663-008-9220-0
[2]   Modgil, A. (2003). Effects of high speed machining on surface topography of titanium alloy (Ti6Al4V) [Doctoral dissertation, University of Florida].
[3]   Das, S., Klotz, M., & Klocke, F. (2003). EDM simulation: finite element-based calculation of deformation, microstructure and residual stresses. Journal of Materials Processing Technology, 142(2), 434-451. https://doi.org/10.1016/S0924-0136(03)00624-1
[4]   Ekmekci, B. (2007). Residual stresses and white layer in electric discharge machining (EDM). Applied Surface Science, 253(23), 9234-9240. https://doi.org/10.1016/j.apsusc.2007.05.078
[5]   Zhu, L., Guan, Y., Wang, Y., Xie, Z., Lin, J., & Zhai, J. (2017). Influence of process parameters of ultrasonic shot peening on surface roughness and hydrophilicity of pure titanium. Surface and Coatings Technology, 317, 38-53. https://doi.org/10.1016/j.surfcoat.2017.03.044
[6]   Xing, X., Duan, X., Jiang, T., Wang, J., & Jiang, F. (2019). Ultrasonic peening treatment used to improve stress corrosion resistance of AlSi10Mg components fabricated using selective laser melting. Metals, 9(1), 103. https://doi.org/10.3390/met9010103
[7]   Hansen, N. (2004). Hall–Petch relation and boundary strengthening. Scripta Materialia, 51(8), 801-806. https://doi.org/10.1016/j.scriptamat.2004.06.002
[8]   Amanov, A., Penkov, O. V., Pyun, Y. S., & Kim, D. E. (2012). Effects of ultrasonic nanocrystalline surface modification on the tribological properties of AZ91D magnesium alloy. Tribology International, 54, 106-113. https://doi.org/10.1016/j.triboint.2012.04.024
[9]   Montgomery, D. C. (2017). Design and analysis of experiments. John wiley & sons.
[10] Abbasi, A., Amini, S., & Sheikhzadeh, G. A. (2018). Effect of ultrasonic peening technology on the thermal fatigue of rolling mill rolls. The International Journal of Advanced Manufacturing Technology, 94, 2499-2513. https://doi.org/10.1007/s00170-017-0840-x
[11] Malaki, M., & Ding, H. (2015). A review of ultrasonic peening treatment. Materials & Design, 87, 1072-1086. https://doi.org/10.1016/j.matdes.2015.08.102
[12] Chen, Y., Liu, F., He, C., Li, L., Wang, C., Liu, Y., & Wang, Q. (2022). Effect of ultrasonic peening treatment on the fatigue behaviors of a magnesium alloy up to very high cycle regime. Journal of Magnesium and Alloys, 10(3), 614-626. https://doi.org/10.1016/j.jma.2021.07.028
Iranian Journal of Materials Forming
Volume 11, Issue 1
January 2024
Pages 44-61

Files

Share

How to cite

Statistics