Study of Wear Characteristics of AISI D2 Steel

Abstract

Here AISI D2 steel is taken into consideration. Its use can be categorized into stamping die material which is being used in many cold roll forming and other press working industries. Its other names are high carbon & high chromium steel. On the pins of D2 steel and disks of Aluminum alloy 6061 the wear experiments were performed. To develop relationships for predicting weight loss of pins because of rubbing action design of experiment based on 2 levels full factorial design along with three independent factors (normal load, sliding speed, sliding time) has been used. With the utmost precision of 10-4 g the weight loss of pins has been measured. Among the topics of high concern to automotive industry the wear of deforming dies continues to be a great concern because increasing die maintenance results increase in cost and scrap rate. As per the current trend the demand to reduce the use of lubricants and increase tool life in sheet metal stamping has lead to increase in research on the sliding contact between the tool and the sheet material. So it has been found out that the deforming conditions, such as - normal load, sliding speed, sliding time etc. leads to much more effect on the performance of operation to a much greater extent. The selection of all these deforming parameters must be carefully done so that optimization of such economics and quality of operations can be carried out easily. This goal can be attained only when the detailed investigation and mathematical modeling of performance as a function of sliding conditions using design of experiments (DOE) is done and implemented in such manner. The main aim of the present work is to grant the permission access to the effect of sliding parameters. The �design expert 8.0.4.1� software has been used for the analysis. With the development of a prediction model the necessary interaction prevailing between sliding parameters can be known. With the help of ANOVA model adequacy tests were conducted, several other effects and various parameters were investigated and presented in the form of contour plots and 3D surface graphs. Along with this, few numerical optimizations have been carried out in which all the input parameters within range were included so as to minimize the weight loss (wear volume). The result obtained by this research work is helpful to manufacturing industry that make use of AISI D2 steel for deforming dies.