Optimization of Dimensional Accuracy of Mold Steel in Wire Cut Process Based on Response Surface Method

One of the industrial parts that requires very high manufacturing accuracy is industrial molds and especially cutting molds. In these molds, the clearance of the dies is equal to 0.1 of the thickness of the sheet, so the accuracy of making these molds is very important. Today, the wirecut process is widely used in making these molds. In the process, due to the lack of contact between the tool and the work piece, there is no mechanical tension and the produced parts have high precision. Nevertheless, in order to achieve the high precision required in the production of cutting molds, various methods are used. In this research, using the response surface method, the dimensional accuracy value has been investigated based on three parameters of wire speed, wire tension and generator power for Mo40 steel workpiece. Based on this method, at first, the importance of each parameter on dimensional accuracy was determined. Then, by deriving the equation according to the conducted tests, the optimal value of dimensional accuracy was extracted based on the mentioned parameters. The results showed that for tension values of 1.3485 kg, wire speed of 10 cm/s and power of 46.7677%, the accuracy value reaches its maximum value. Finally, these values were experimentally tested and a 0.2% error was recorded. Therefore, by using the method of the response procedure, the amount of dimensional accuracy can be used in the wirecut process of industrial steel molds.