Experimental investigation of the effect of machining parameters over cutting force and surface roughness in the machinability of AA5052 alloy

Bu çalışmada, AA5052 serisi alüminyum alaşımının, kaplamasız sementit karbür takımla işlenmesinde farklı kesme ve ilerleme hızlarının, talaş kaldırma kuvvetlerinden esas kesme kuvveti ve ortalama yüzey pürüzlülüğü üzerindeki etkileri incelenmiştir. Deneylerde sabit kesme derinliği (1.5 mm), dört farklı kesme hızı (200, 300, 400, 500 m/min) ve beş faklı ilerleme hızı (0.10, 0.15, 0.20, 0.25, 0.30 mm/rev) kullanılmıştır. Yapılan deneylerde kesme ve ilerleme hızına bağlı olarak ortalama en düşük esas kesme kuvveti 500 m/min kesme hızı ve 0.10 mm/rev ilerleme hızında 113 N, en yüksek kesme kuvveti ise 200 m/min kesme hızı ve 0.30 mm/rev ilerleme hızında 332 N elde edilmiştir. En düşük ortalama yüzey pürüzlülüğü 200 m/min kesme hızı ve 0.10 mm/rev ilerleme hızında 0.95 ($\mu m$, en yüksek ortalama yüzey pürüzlülüğü ise 300 m/min kesme hızı ve 0.30 mm/rev ilerleme hızında 6.65 $\mu m$ elde edilmiştir.In this study, the effects of different cutting and feed rates over average surface roughness and main cutting force during the machinability of AA5052 aluminum alloy with uncoated cemented carbide insert were evaluated. In the experiments, stable depth of cut (1.5 mm), four different cutting speeds (200, 300, 400, 500 m/min) arid five different feed rates (0.10, 0.15, 0.20, 0.25, 0.30 mm/rev) were used. Based on cutting and feed rates, the lowest main cutting force was obtained as 113 in 500 m/min cutting speed and 0.10 mm/rev feed rate and the highest cutting force was obtained as 332 N in 200 m/min cutting speed and 0.30 mm/rev feed rate. The lowest average surface roughness was obtained as 0.95 $\mu m$ in 200 m/min cutting speed and 0.10 mm/rev feed rate and the highest average surface roughness was obtained as 6.65 $\mu m$ in 300 m/min cutting speed and 0.30 mm/rev feed rate

THE EFFECT OF CORE CONFIGURATION ON THE COMPRESSIVE PERFORMANCE OF METALLIC SANDWICH PANELS

WOS: 000510203200017The compressive performance of metallic sandwich panels signifies a key mechanical behaviour under compression loading. This paper describes the compressive performance of metallic corrugated core sandwich panels having different core configurations under quasi-static compression loads. Two different sandwich panel core configurations were studied: the corrugated monolithic core and the corrugated sliced core. The corrugated cores were fabricated using a sheet-metal bending technique with trapezoidal geometry and then bonded to surface plates. Aluminium 1050 1114 sheets were used as the core and surface materials. Sandwich panel samples were prepared and tested experimentally under a quasi-static compression load (compression rate of 2 mm/min). The force-displacement curves of the sandwich panels with different core configurations were obtained from the experimental tests. The compressive performance parameters included the maximum compression load, the average compression load, the energy absorption and the specific energy absorption. It was found that the core configuration played a key role in the compressive performance. Finally, when the compressive performance of these two different core configurations was compared, the corrugated sliced-core configurations exhibited better performance.Karabuk University Coordinatorship of Research Projects, Karabuk, Turkey [KBUBAP-17-DR-458]This work was supported by the Karabuk University Coordinatorship of Research Projects, Karabuk, Turkey (No. KBUBAP-17-DR-458)

Experimental investigation of the effects of cutting tool coating materials on surface roughness in machining of AISI 1040 steel

Bu çalışmada, farklı kesici takım kaplama malzemesinin farklı işleme parametrelerine bağlı olarak iş parçasının yüzey kalitesi üzerindeki etkileri araştırılmıştır. Bu amaçla, AISI 1040 çeliği; PVD yöntemiyle $Al_2O_3$ kaplanmış, CVD yöntemiyle üç katlı kaplama uygulanmışken üstte TiN kaplı) iki farklı sementit karbür takımla torna tezgahında, soğutma sıvısı kullanılmadan işlenmiştir. Kesme parametrelerinden kesme derinliği sabit tutularak (2.5 mm) beş farklı kesme hızı (58, 83, 116, 163, 225 m/min) ve iki farklı ilerleme (0.24, 0.32 mm/rev) değerlerinde talaş kaldırma işlemleri gerçekleştirilerek bu parametrelerin yüzey pürüzlülüğü üzerindeki etkileri incelenmiştir. Yapılan deneylerde en düşük ortalama yüzey pürüzlülüğü en üstte TiN kaplı üç katlı kaplamaya sahip takımla elde edilmiştir. İlerleme miktarının %33 artırılmasıyla ortalama yüzey pürüzlülüğünde %14 artış gözlenmiş, kesme hızının %388 artırılması-ise yüzey pürüzlülüğünde %114 iyileşme elde edilmiştir.In this study, the effects of different cutting tool coating materials on surface roughness of work piece were investigated as well as the cutting parameters. For this purpose, AISI 1040 steel was machined by two different cemented carbide cutting tools coated with $Al_2O_3$ by PVD (Physical Vapour Deposition) and triple coated (TiN on uppermost) by CVD (Chemical Vapour Deposition) and no coolant was used in turning operations. In these tests, five different cutting speed values (58, 83, 116, 163, 225 m/min) and two different feed rate values (0.24, 0.32 mm/rev) were used with constant depth of cut (2.5mm). According to test results the minimum average surface roughness was obtained with the cutting tool having triple coating on uppermost TiN. 14% improvement: was observed in average surface roughness by increasing the feed rate 33% and 114% improvement was obtained by increasing the cutting speed 388%

Mechanical and physical properties of hybrid reinforced (Al/B4C/Ni(K)Gr) composite materials produced by hot pressing

NAS, Engin/0000-0002-4828-9240WOS: 000354792300006In this study, the mechanical and physical properties of hybrid reinforced (Al/B4C/Ni(K)Gr) metal matrix composite (MMC) materials were investigated. The MMC materials were produced using the powder metallurgy (PM) production method of hot pressing (HP). The aluminum alloy Alumix 13 was used as matrix material and boron carbide (B4C) and nickel-coated graphite (Ni(K) Gr) as reinforcement elements. The microstructural characteristics, hardness, 3-point bending strength and density values of the produced hybrid reinforced MMC materials were determined. The reinforcement element B4C was kept at constant concentration of 8 wt.-%. Four different MMC materials were produced with the addition of 0, 3, 5 and 7 wt.-% Ni(K) Gr in the B4C. From the SEM images of the MMC materials produced by the HP technique, it was observed that the reinforcement element exhibited a uniform distribution. Moreover, the particles showed an approach to each other depending on the particle size and the amount (wt.-%) of the reinforcement element. With increasing graphite content in the structure density, hardness and 3-point bending test values decreased.Karabuk University Scientific Research Project DivisionKarabuk University [KBU-BAP-13/2-DR-012]The authors wish to place their sincere thanks to Karabuk University Scientific Research Project Division for financial support for the Project No.: KBU-BAP-13/2DR-012

EXPERIMENTAL INVESTIGATION OF THE TOOL-CHIP INTERFACE TMPERATURES ON UNCOATED CEMENTIDE CARBIDE CUTTING TOOLS

It is known that the temperature as the result of the heat developed during machining at the tool-chip interface has an influence on the tool life and workpiece surface guality and the methods for measuring this temperature are constantly under investigation. In this study, the measurement of tool-chip interface temperature using toolworkpiece termocouple method was investigated. The test were carried out on a AISI 1040 steel and the toolchip interface temperature variation was examined depending on the cutting speed and feed rate. The obtained groups show that cutting speed has more influence on the temperature than feedrate has

Aısı 1040 Çeliğinin Aşındırıcı Su Jeti İle tornalama İşleminde İşleme Paremetrelerinin Talaş Kaldırma Hacmine Ve Kesme Derinliğine Etkisi

Bu çalışmada, AISI 1040 çeliğinin aşındırıcı su jeti ile tornalanması esnasında işleme parametrelerinin kaldırılan talaş hacmime ve kesme derinliğine etkisi araştırılmıştır. Yapılan çalışmada deney sayısının en az olması için literatürde yapılmış olan çalışmalar göz önüne alınmış ve ön deneyler sonucu elde edilen tecrübelerle en uygun işleme parametre değerleriyle deneyler gerçekleştirilmiştir. Deneysel çalışmalarda pompa basıncı (350 MPa), aşındırıcı boyutu (Garnet formunda ve boyutu 80 mesh) ve nozul çapı (1.2 mm) sabit tutulmuştur. Ø 30 ve 240 mm ebatlarında 1040 çeliği, dört farklı aşındırıcı akış oranı (50, 150, 250 ve 350 gr/dak.), nozul mesafesi (2, 5, 8 ve 11 mm), nozul ilerleme miktarı (5, 15, 25 ve 35 mm/dak.) ve torna aynası deviri (25, 50, 75 ve 100 dev/dak.) işleme parametreleri değerlerinde işlenmiştir. Elde edilen bulgulara göre en yüksek talaş hacmi 5 mm/dak nozul ilerleme miktarında 1387,25 mm3 elde edilmiştir. En yüksek kesme derinliği ise 0,94 mm olarak 100 dev/dak torna aynası devrinde elde edilmiştir

Termal bariyer kaplamanin motor yakit sarfiyati egzoz sicakliği ve emisyonlara etikilerinin deneysel olarak incelenmesi

Bu çalışmada, hava soğutmalı, tek silindirli, doğrudan püskürtmeli, 4 zamanlı ve marşlı Solax marka 178FE tipi dizel motorunun yanma odası elemanlarının termal bariyer malzemelerle kaplanması ve 1600 1/min ile 3200 1/min hızları arasında 400 1/min hız aralıklarında ve tam yük şartları altında % 100 dizel yakıtı ile denenmesi ve termal bariyer kaplamaların motorun egzoz gaz sıcaklığına, egzoz emisyonlarına ve yakıt sarfiyatına etkilerinin belirlenmesi amaçlanmıştır. Motor hızının artmasına ve kaplama malzemelerine bağlı olarak egzoz gaz sıcaklığının arttığı, çevreye ve canlılara zararlı olan HC ve CO emisyonlarının azaldığı ve yakıt sarfiyatında iyileşme olduğu tespit edilmiştir

Investigating the effects of cutting speeds over the built-up layer and built-up edge formation with SEM

Bu çalışmada, işleme parametrelerinden kesme hızının Yığıntı Katmanı (Built-Up layer) (YK) ve Yığıntı Talaş (Built-Up Edge) (YT) oluşumu üzerindeki etkileri araştırılmıştır. Bu amaçla, AA5052 alaşımı; kaplamasız karbür takımla bilgisayarlı sayısal denetimli (BSD) torna tezgahında, kuru olarak işlenmiştir. Deneylerde, beş farklı kesme hızı (100, 200, 300, 400, 500 m/min), sabit ilerleme hızı (0,30 mm/dev) ve sabit kesme derinliği (1.5 mm) işleme parametreleri olarak seçilmiştir. Talaş kaldırma işlemleri sonucunda, kesici takım üzerinde en fazla YK ve YT, 100 m/min kesme hızı ve 0,30 mm/dev ilerleme hızında yapılan talaş kaldırma işleminde oluştuğu tespit edilmiştir. Kesme hızının artırılması YK ve YT oluşumunu azaltmış, fakat denenen sınırlar içerisinde YK ve YT oluşumu engellenememiştir.In this study, the effects of cutting speed; over the formation of Built-Up Layer (BUL) and Built-Up Edge (BUE) were investigated. For this purpose, AA5052 alloy was processed on a Computer Numeric Control (CNC) lathe with uncoated cemented carbide insert in dry conditions. As processing parameters in the experiments, five different cutting speeds (100, 200, 300, 400, 500 m/min), constant feed rate (0,30 mm/rev) and connstant depth of cut (1,5 mm) were selected. As the result of the experiments, it was stated that BUL and BUE were formed on cutting tool mostly in machining at 100 m/min cutting speed and 0,30 mm/rev feed rate. Increasing the cutting speed decreased BUL and BUE formation but they could not be stopped in the tested range

A review on machinability of carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) composite materials

Fiber reinforced polymer (FRP) composite materials are heterogeneous and anisotropic materials that do not exhibit plastic deformation. They have been used in a wide range of contemporary applications particularly in space and aviation, automotive, maritime and manufacturing of sports equipment. Carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) composite materials, among other fiber reinforced materials, have been increasingly replacing conventional materials with their excellent strength and low specific weight properties. Their manufacturability in varying combinations with customized strength properties, also their high fatigue, toughness and high temperature wear and oxidation resistance capabilities render these materials an excellent choice in engineering applications. In the present review study, a literature survey was conducted on the machinability properties and related approaches for CFRP and GFRP composite materials. As in the machining of all anisotropic and heterogeneous materials, failure mechanisms were also reported in the machining of CFRP and GFRP materials with both conventional and modern manufacturing methods and the results of these studies were obtained by use of variance analysis (ANOVA), artificial neural networks (ANN) model, fuzzy inference system (FIS), harmony search (HS) algorithm, genetic algorithm (GA), Taguchi's optimization technique, multi-criteria optimization, analytical modeling, stress analysis, finite elements method (FEM), data analysis, and linear regression technique. Failure mechanisms and surface quality is discussed with the help of optical and scanning electron microscopy, and profilometry. ANOVA, GA, FEM, etc. are used to analyze and generate predictive models. Keywords: Composite materials, Fiber reinforced polymer composite materials, CFRP, GFRP, Machining, Wear, Surface damag

The effect of coating material and geometry of cutting tool and cutting speed on machinability properties of Inconel 718 super alloys

In this study, the effects of cutting tool coating material and cutting speed on cutting forces and surface roughness are investigated. For this purpose, nickel based super alloy Inconel 718 is machined at dry cutting conditions with three different cemented carbide tools in CNC lathe. Metal removing process is carried out for five different cutting speeds (15, 30, 45, 60, 75 m/min.) while 2 mm depth of cut and 0.20 mm/rev feed rate are to be constant. Main cutting force, Fc is considered to be cutting force as a criterion. In the experiments, depending on the tool coating material, lowest main cutting force is found to be 506 N at 75 m/min with multicoated cemented carbide insert whose top layer is coated by Al2O3. Lowest average surface roughness (0.806 µm) is obtained at the cutting speed of 15 m/min with single coated (TiN) cemented carbide inserts. © 2006 Elsevier Ltd. All rights reserved