In metal forming processes, surface roughness plays a vital role in deciding the efficiency of the process. A rough surface results in more power loss and abrasion in dies and punches during metal forming operations. In the present work, the magnetorheological fluid-based finishing process is used to finish the industrial tube extrusion punch made of hardened H13 die steel material. A magnetorheological solid core rotating tool has been used in the process. Process parameters for AISI H13 steel have been optimized using response surface methodology. For the study of process parameters optimization, specimens in the form of pieces are prepared. These specimens maintain the same surface roughness and hardness as that of the industrial extrusion punch. The effect of various process parameters on the percentage change in average surface roughness of H13 die steel is analyzed and has optimized the parameters for better process performance. Experiments are performed using optimum parameters to examine the process performance with respect to time on the H13 die steel specimen. Change in surface morphology is also analyzed using scanning electron microscopy. The optimized parameters are then used to finish the industrial tube extrusion punch on the designed fixture. By using the optimized parameters, the surface finish of the industrial extrusion punch is reduced to 70 nm from 480 nm in 23 h. After magnetorheological finishing on the extrusion punch, the punch is taken in the industry to check the effect of reduction in surface roughness during the extrusion process. It is found that power consumption has been reduced by 25%. There is also an improvement in extrusion punch life. The magnetorheological finished extrusion punch now extruded more almost 3515–3520 tube spindles as compared to 3300–3500 with ground extrusion punch.
Extrusion punch Magnetorheological polishing fluid H13 die steel Surface roughness
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