Flattening with diamonds optimises hardened steel surfaces of tools and moulds

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Concluding analyses

Finally, tests were carried out on the workpiece hardness according to Vickers H_v,w as a function of the feed rate v_f. A lateral infeed of a_e = 90 µm and a process force of F_Pr = 90 N were used. In the parameter range considered, workpiece hardnesses according to Vickers could be documented in a range between 693.8 HV10 ≤ H_v,w ≤ 799.3 HV10, which are shown in Fig. 1-3c. The highest workpiece hardness of H_v,w = 799.3 HV10 could be observed on average at a feed rate of v_f = 6000 mm/min, whereby the variation of the feed rate v_f has no significant influence on the change of the workpiece hardness according to Vickers H_v,w.

Summary and outlook

The overall objective of the research was to develop a dedicated technology for the targeted finishing of the steel material Elmax Superclean of type PMX170CrVMo18-3-1 while maintaining arithmetic centre-line roughness values Ra ≤ 80 nm at significantly increased feed rates of v_f ≥ 6000 mm/min. For the research, the arithmetic centre-line roughness Ra was analysed as a function of the process force F_Pr, the feed rate v_f and the lateral infeed a_e, whereby suitable process parameters for finishing were identified and a significant reduction of the arithmetic centre-line roughness Ra = 94.3 percent was achieved. In addition to the influence on the surface quality, it was shown that the flattening process also has a significant influence on the workpiece hardness according to Vickers H_v,w in the surface-near boundary layer and that significant increases in hardness of up to 21 percent can be achieved.

Due to the engagement conditions resulting in the forming process as a result of the application of the flattening technology, residual compressive stresses σ_D are also introduced into the material, which prevents the release of residual stresses σ and thus component distortion during post-processing. Based on the results, it was possible to develop a dedicated process chain, consisting of milling and downstream smoothing with PCD, for the economic finishing of the steel material Elmax Superclean with arithmetic centre-line roughness values of Ra ≤ 80 nm and feed rates of v_f ≥ 6000 mm/min. Building on these findings, further material-specific analyses and a detailed wear analysis of the tool used with a smooth spinning head made of PCD are to be researched in future scientific studies.

Note: The original title of this article is: „Oberflächennachbearbeitung gehärteter Stahlwerkstoffe durch Glattdrücken mit polykristallinem Diamanten“. More about flattening

Literature

[BEL13] Bellantone, V.; Surface, R.; Trotta, G.; Fassi, I.: Replication capability of micro injection moulding process for polymetric parts manufacturing. The International Journal of Advanced Manufacturing Technology (2013), S. 1.407 – 1.421.

[KLC05] Klocke, F.; Von Bodenhausen, J.; Arntz, K.: Prozesssicherheit bei der Mikrofräsbearbeitung - Herausforderung für den Mikroformenbau. wt Werkstattstechnik Nr. 11/12, 2005, online 95, S. 882 – 886.

[REI13] Reinhardt, P.: Wachstumsmarkt Medizintechnik: Zugang, Anwendung und Prozesse. Vogel Business Media GmbH & Co.KG., 2013.

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Date: 08.12.2025

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Surface Quality of Moulds