Design, manufacturing and plasma nitriding of AISI-M2 steel forming tool and its performance analysis

TLDR

Mechanical manufacturing transforms metals into parts using tools for cutting, punching, and stamping, and the useful life of these tools ends when their cutting edges wear out; forming tools can be made from AISI‑M2 high‑speed steel and their surface properties can be altered by thermal and thermochemical treatments. The study aims to design and fabricate a forming tool in the laboratory without using CNC machines. The fabricated tools were plasma nitrided at 400–500 °C and their performance was compared to an existing factory‑produced tool. Plasma nitriding, particularly at 400 °C, significantly increased hardness, wear resistance, and nail production, making the lab‑made tool easier to manufacture, eco‑friendly, and cost‑effective compared to the factory tool.

Abstract

Mechanical manufacturing processes aim to transform metallic materials into mechanical parts and components. In these processes, tools are used for cutting, punching and stamping. The ending of the useful lifetime of these tools happens with wear of its cutting edge. Such forming tools can be manufactured by several materials including AISI-M2 high-speed steel steels, and their surface properties can be modified by thermal and thermochemical treatments. In this study, an attempt is made to design and manufacture a forming tool in the laboratory without usage of computer numerical control machines. Afterwards, the manufactured forming tools are plasma nitrided at various temperatures (400–500 °C) and obtained results are compared with existing tool provided by nails manufacturing factory. The forming tools after plasma nitriding show a significant hardness improvement, increased nails production (used in civil construction), and better wear resistance as compared to the existing tool, particularly at 400 °C. The forming tool obtained in this study is easy-to-manufacture, eco-friendly plasma treatment and cost-effective, and thus it is expected that it can resolve company's technical issue regarding premature wear and tear, and rapid replacement of tool in nails manufacturing.