Surface integrity of AISI D2 when machined with plasma assisted machining

Ahmad Rozi, Shahrain (2015) Surface integrity of AISI D2 when machined with plasma assisted machining. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This study reports on the surface integrity of AISI D2 when machined using plasma assisted machining. The purpose of this study were to analyse the microstructure, Heat Affected Zone ( HAZ) and microhardness of AISI D2 after heated by plasma cutting. Despite the great qualities produced by plasma cutting, the drawback from this operation was that the high temperature of plasma cutting modify the surface integrity of the material.When AISI D2 was exposed to the hight temperature of plasma cutting operation, there were changes occur at subsurface layer. Due to the alteration of the microstructure, the properties in the sub-surface zone are also different from those of the bulk material. The changes of the properties affects on the surface integrity. The changes of surface integrity affects to the performance of material In this study,AISI D2 was machined at different cutting condition which were current flow rate, feed rates, air pressure and standoff distance.The machine and equipment used in this study were CNC milling machine with plasma torch attach on it, EDM wire cut, Buehler Simplimet 3000 automatic mounting press machine and Scanning Electron Microscopes (SEM). From this experiment, the following findings have been discovered, the effect from the high operating temperature of plasma cutting produced two regions which are Heat Affected Zone and non -Heat Affected Zone. HAZ). The most significant parameter that influence on the HAZ were current flow rate, followed by feed rates. Meanwhile air pressure and stand off distance gave less effect on the thickness of HAZ. Apart from that, the microhardness value at HAZ region varied from the microhardness at the bulk material in which the microhardness HAZ region was much more higher than the microhardness at bulk material.

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