Purpose

Wire electric discharge machining (WEDM) is a non-conventional machining process, which is used for cutting parts of civil and military aircraft, rotorcraft, satellites and spacecraft. The cold work steel X153CrMoV12 is used in molds that are needed to produce plastic and metal parts used in these areas. It is only possible to produce parts with precise dimensions and quality with the use of mold steels with sensitive surfaces. The purpose of this study is to analyze X153CrMoV12 material by cutting it with WEDM method in precise dimensions.

Design/methodology/approach

The effects of varying cutting parameters on the size of the finished product, surface roughness (SR) and surface hardness were determined by making rough in one pass and precision cuts in different passes. Nikon SMZ745T, Mitutoyo micrometer, Mitutoyo SJ-210 and Insize ISHL-P100 were used for macro-analysis, dimensional control, SR and surface hardness, respectively, to determine the cut qualities.

Findings

According to the hardness measurement results obtained from the steel surface before cutting and from the cut surfaces after cutting, there was no significant change in the surface hardness owing to the use of heat-treated steel. Increasing the wire tension as a result of the increase in the number of cutting passes and the decrease in the amount of rough stock left for the final cut increased the cut quality. Cutting precision has increased by preventing vibration of the wire with zero upper and lower water pressure required for slag cleaning.

Originality/value

There are many studies on WEDM in the literature, but there is no similar study emphasizing the importance of the processing parameters such as the number of cutting passes and rough stock amount. In this study, cold work steel with a hardness of 56–60 HRC was machined as rough cut in one pass, rough and fine cut in double pass, double fine cut after one roughing in three passes. As a result of the cuts, 3 µm measurement precision and 0.998 Ra SR were obtained as well as there was no hardness change in the cut surfaces.

中文翻译：

---

线切割加工冷作钢X153CrMoV12的研究

目的

线切割加工（WEDM）是一种非常规加工工艺，用于切割民用和军用飞机、旋翼机、卫星和航天器的零件。冷作钢 X153CrMoV12 用于生产这些领域使用的塑料和金属零件所需的模具。只有使用具有敏感表面的模具钢才能生产出具有精确尺寸和质量的零件。本研究的目的是对 X153CrMoV12 材料进行精确尺寸的 WEDM 切割方法的分析。

设计/方法/方法

不同切削参数对成品尺寸、表面粗糙度 (SR) 和表面硬度的影响是通过一次粗加工和多道精密切削来确定的。Nikon SMZ745T、Mitutoyo 千分尺、Mitutoyo SJ-210 和 Insize ISHL-P100 分别用于宏观分析、尺寸控制、SR 和表面硬度，以确定切割质量。

发现

根据切削前钢材表面和切削后切削面的硬度测量结果，由于使用了热处理钢，表面硬度没有显着变化。由于切割次数的增加和用于最终切割的毛坯量的减少而增加了线张力，从而提高了切割质量。通过在清渣所需的上下水压为零的情况下防止线振动，提高了切割精度。

原创性/价值

文献中有很多关于线切割机床的研究，但没有类似的研究强调切削道次和毛坯量等加工参数的重要性。在这项研究中，硬度为 56-60 HRC 的冷作钢被加工为一次粗切削，双道次粗切削和精切削，三道次粗加工一次后双精切削。切割的结果是，获得了 3 µm 的测量精度和 0.998 Ra SR，并且切割面没有硬度变化。