Flattening with diamonds optimises hardened steel surfaces of tools and moulds

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Effects on the near-surface boundary layers

In addition to demonstrating a significant reduction in the surface roughness parameters of up to 94.3 percent during the finishing of the steel material Elmax Superclean, changes in the surface-near boundary layer in the form of hardness increases due to the flattening process could also be demonstrated. Thus, the surface roughness parameters can be significantly reduced and the workpiece hardness according to Vickers H_v,w can be increased by up to 21.2 percent. The surfaces A produced by flattening were analysed with the small hardness tester Miniload 2 from Ernst Leitz Wetzlar from Wetzlar, Germany, according to the Vickers method. Figure 1-2 shows the workpiece hardness according to Vickers H_v,w as a function of the feed rate v_f, the process force F_Pr and the lateral infeed a_e.

Fig. 1-2: Workpiece hardness according to Vickers as a function of the process force, the lateral infeed and the feed rate.(Spource: TU Berlin) — Fig. 1-2: Workpiece hardness according to Vickers as a function of the process force, the lateral infeed and the feed rate.
(Spource: TU Berlin)

For the examination of the workpiece hardness according to Vickers H_v,w as a function of the lateral infeed a_e in Fig. 1-2a, a process force of F_Pr = 90 N and a feed rate of vf = 6000 mm/min were used. The average workpiece hardness according to Vickers H was between 693.8 HV10 ≤ H_v,w ≤ 841.3 HV10. The highest workpiece hardness H_v,w = 841.3 HV10 was measured at a lateral infeed of a_e = 10 µm. This shows that an increase in the lateral infeed a_e is accompanied by a reduction in the workpiece hardness H_v,w according to Vickers. This can be attributed to the number of superimposed flattening paths a_GDB, whereby the total surface AG is reformed several times with a reduced lateral infeed a_e.

Using a lateral infeed of a_e = 90 µm and a feed rate of vf = 6000 mm/min, the progression of the workpiece hardness according to Vickers H_v,w as a function of the process force F_Pr was documented in Fig. 1-2b. On average, a workpiece hardness according to Vickers in a range of 693.8 HV10 ≤ H_v,w ≤ 805.2 HV10 was measured, whereby a linear progression with increasing process force F_Pr can be observed. The highest workpiece hardness H_v,w = 805.2 HV10 could be determined at a process force F_Pr = 90 N.

In general, it can be seen that increasing the process force F_Pr causes the highest increase in workpiece hardness according to Vickers H_v,w. This is due to the increased surface pressure p_B with increasing process forces F_Pr, which significantly influences the forming process and enables a targeted increase in hardness.

(ID:47897953)

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Date: 08.12.2025

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Surface Quality of Moulds

Effects on the near-surface boundary layers

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