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Investigation of the Effect of Cutting Parameters and Tool Holder on Surface Roughness and Machining Precision in Al 7075-T6 Milling Operation

Year 2023, Volume: 9 Issue: 3, 535 - 543, 01.01.2024

Abstract

Aluminium alloys are widely used in various manufacturing industries due to their unique light weight performance, high strength-to-weight ratio, and high corrosion resistance, Therefore, aluminium alloys should be well studied during machining, and examined how to obtain a wellmachined surface and increase processing precision. In this study, the effects of cutting parameters (cutting speed, feed rate, peripheral depth of cut, and tool holder type) on surface roughness and processing precision in CNC milling of Al 7075-T6 alloy were investigated using the Taguchi L27 method. In addition, variance analysis (ANOVA) was performed to find the effect ratios of cutting parameters on surface roughness and processing precision. As a result, it was observed that the largest effect ratio of the peripheral depth of cut on surface roughness and processing precision was 37.7 % and 36.1 %, respectively. The used tool holders did not have any effect on the surface roughness of the work-piece. However, a tool holder type has played a significant role in processing precision. The hydraulic tool holder has provided maximum processing precision, while the mechanical tool holder has showed a minimum precision level of the machining work-pieces.

References

  • [1] D. B. Prakash, G. R. Balaji and A. G., Chand, “Optimization of machining parameters for aluminium alloy 6082 in CNC end milling,” International Journal of Engineering Research and Applications, vol. 3, pp. 505-510, 2013.
  • [2] M.P. Groover, Fundamentals of modern manufacturing: Materials, Processes, and Systems, Fourth Edition, Wiley, 2002.
  • [3] F. Puh, Z. Jurkovic, M. Perinic, M. Brezocnik and S. Buljan, "Optimization of machining parameters for turning operation with multiple quality characteristics using Grey relational analysis," Teh. Vjesn., vol. 23, no. 2, pp. 377–382, 2016. doi:10.17559/TV-20150526131717
  • [4] S. Sakthivelu, M. Meignanamoorthy, M. Ravichandran and M. Kumar, "Effect of machining parameters on surface roughness and material removal rate in CNC end milling," International Journal of Scientific Research and Engineering Studies, vol. 2, no. 4, 2015.
  • [5] A. Zerti, M. A. Yallese, O. Zerti, M. Nouioua and R. Khettabi, "Prediction of machining performance using RSM and ANN models in hard turning of martensitic stainless steel AISI 420," Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci., vol. 233, no. 13, pp. 4439–4462, 2019. doi:10.1177/09544062188205
  • [6] G. Mahesh, S. Muthu, and S. R. Devadasan, “Prediction of surface roughness of end milling operation using genetic algorithm,” Int J Adv Manuf Technol, vol. 77, pp. 369–381, 2015. doi:10.1007/s00170-014-6425-z
  • [7] P. Raj, A. P. Perumal and E. P. Ramu, “Prediction of surface roughness and delamination in end milling of GFRP using mathematical model and ANN,” Indian Journal of Engineering and Materials Sciences, vol. 19, pp. 107–120, 2012.
  • [8] Y. Şahin, A. C. Kocabıçak and S. Yalçınkaya, “Prediction of Surface Finish Model in Cutting AISI 4140 Steel with Different Approaches” in Proceedings of the 9th International Conference on Fracture, 2021, Singapore, 2021, Singapore: Springer, 2021. pp. 303-318.
  • [9] P. Palanisamy, I. Rajendran and S. Shanmugasundaram, "Prediction of tool wear using regression and ANN models in end-milling operation," Int. J. Adv. Manuf. Technol., vol. 37, pp. 29–41, 2008. doi:10.1007/s00170-007-0948-5
  • [10] A. M. Zain, H. Haron and S. Sharif, "Application of regression and ANN techniques for modeling of the surface roughness in end milling machining process," Third Asia International Conference on Modelling and Simulation, 2009, pp. 188–193.
  • [11] K. Khalil, A. Mohd, C. O. C. Mohamad, Y. Faizul and S. Z. Ariffin, "The Optimization of Machining Parameters on Surface Roughness for AISI D3 Steel," in Journal of Physics: Conference Series, vol. 1874, no. 1, pp. 12063, 2021. doi:10.1088/1742-6596/1874/ 1/012063
  • [12] L. Nisar, B. Banday, M. Amatullah, M. Farooq, A. N. Thoker, A. Maqbool and M. A. Wahid, "An investigation on effect of process parameters on surface roughness and dimensional inaccuracy using Grey based Taguchi method," Mater. Today Proc., vol. 46, pp. 6564–6569, 2021. doi:10.1016/j.matpr.2021.04.040
  • [13] L. H. Kashkool, "Optimization of Machining Parameters of AISI 1045 Steel for Better Surface Finish and Tool Life Using TiN Coated Carbide Insert," Tikrit J. Eng. Sci., vol. 29, no. 2, pp. 1–6, 2022. doi:10.25130/tjes.29.2.1
  • [14] E. Akdeniz and H. Arslan, “A new design of boring bar using TiNi3 alloy to reduce vibration in turning operations,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 237, no. 1-2, 2023, pp.105-121. doi:10.1177/0954405 4221104607

AL 7075-T6 Frezeleme Operasyonunda Kesme Parametrelerinin Ve Takım Tutucunun Yüzey Pürüzlülüğüne Ve İşleme Hassasiyetine Etkisinin İncelenmesi

Year 2023, Volume: 9 Issue: 3, 535 - 543, 01.01.2024

Abstract

Alüminyum alaşımları, benzersiz hafiflik performansları, yüksek mukavemet/ağırlık oranı ve yüksek korozyon direnci nedeniyle çeşitli imalat endüstrilerinde yaygın olarak kullanılmaktadır. Bu nedenle alüminyum alaşımları talaşlı imalat sırasında iyi araştırılmalı, iyi bir işlenmiş yüzeyinin nasıl elde edileceği ve işleme hassasiyetini nasıl artırılacağı incelenmelidir. Bu çalışmada, AL 7075-T6 alaşımının CNC frezelemesinde kesme parametrelerinin (kesme hızı, ilerleme, yan kesme derinliği ve takım tutucu türü) yüzey pürüzlülüğüne ve işleme hassasiyetine etkileri, Taguchi L27 yöntemi kullanarak incelenmiştir. Ayrıca, kesme parametrelerin yüzey pürüzlülüğüne ve işleme hassasiyetine etki oranlarını bulmak için variyans analizi (ANOVA) yapılmıştır. Sonuç olarak, yan kesme derinliğinin yüzey pürüzlülüğü ve işleme hassasiyeti üzerindeki etkilerine bakıldığında, en büyük etkinin sırasıyla %37,7 ve %36,1 olduğu görülmüştür. Kullanılan takım tutucu çeşitlerinin yüzey pürüzlülüğüne etkisi olmadığı gözlemlenmiştir. Ayrıca, takım tutucu çeşitleri, işleme hassasiyetinde büyük bir rol oynamıştır. Hidrolik takım tutucu, işleme hassasiyetinde maksimum performans sağlarken, mekanik takım tutucu ise işlenen parçanın minimum hassasiyet seviyesini göstermiştir.

Thanks

Sinerji Silah ve Mühimmat A.Ş. Ar-Ge merkezi, Kırıkkale

References

  • [1] D. B. Prakash, G. R. Balaji and A. G., Chand, “Optimization of machining parameters for aluminium alloy 6082 in CNC end milling,” International Journal of Engineering Research and Applications, vol. 3, pp. 505-510, 2013.
  • [2] M.P. Groover, Fundamentals of modern manufacturing: Materials, Processes, and Systems, Fourth Edition, Wiley, 2002.
  • [3] F. Puh, Z. Jurkovic, M. Perinic, M. Brezocnik and S. Buljan, "Optimization of machining parameters for turning operation with multiple quality characteristics using Grey relational analysis," Teh. Vjesn., vol. 23, no. 2, pp. 377–382, 2016. doi:10.17559/TV-20150526131717
  • [4] S. Sakthivelu, M. Meignanamoorthy, M. Ravichandran and M. Kumar, "Effect of machining parameters on surface roughness and material removal rate in CNC end milling," International Journal of Scientific Research and Engineering Studies, vol. 2, no. 4, 2015.
  • [5] A. Zerti, M. A. Yallese, O. Zerti, M. Nouioua and R. Khettabi, "Prediction of machining performance using RSM and ANN models in hard turning of martensitic stainless steel AISI 420," Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci., vol. 233, no. 13, pp. 4439–4462, 2019. doi:10.1177/09544062188205
  • [6] G. Mahesh, S. Muthu, and S. R. Devadasan, “Prediction of surface roughness of end milling operation using genetic algorithm,” Int J Adv Manuf Technol, vol. 77, pp. 369–381, 2015. doi:10.1007/s00170-014-6425-z
  • [7] P. Raj, A. P. Perumal and E. P. Ramu, “Prediction of surface roughness and delamination in end milling of GFRP using mathematical model and ANN,” Indian Journal of Engineering and Materials Sciences, vol. 19, pp. 107–120, 2012.
  • [8] Y. Şahin, A. C. Kocabıçak and S. Yalçınkaya, “Prediction of Surface Finish Model in Cutting AISI 4140 Steel with Different Approaches” in Proceedings of the 9th International Conference on Fracture, 2021, Singapore, 2021, Singapore: Springer, 2021. pp. 303-318.
  • [9] P. Palanisamy, I. Rajendran and S. Shanmugasundaram, "Prediction of tool wear using regression and ANN models in end-milling operation," Int. J. Adv. Manuf. Technol., vol. 37, pp. 29–41, 2008. doi:10.1007/s00170-007-0948-5
  • [10] A. M. Zain, H. Haron and S. Sharif, "Application of regression and ANN techniques for modeling of the surface roughness in end milling machining process," Third Asia International Conference on Modelling and Simulation, 2009, pp. 188–193.
  • [11] K. Khalil, A. Mohd, C. O. C. Mohamad, Y. Faizul and S. Z. Ariffin, "The Optimization of Machining Parameters on Surface Roughness for AISI D3 Steel," in Journal of Physics: Conference Series, vol. 1874, no. 1, pp. 12063, 2021. doi:10.1088/1742-6596/1874/ 1/012063
  • [12] L. Nisar, B. Banday, M. Amatullah, M. Farooq, A. N. Thoker, A. Maqbool and M. A. Wahid, "An investigation on effect of process parameters on surface roughness and dimensional inaccuracy using Grey based Taguchi method," Mater. Today Proc., vol. 46, pp. 6564–6569, 2021. doi:10.1016/j.matpr.2021.04.040
  • [13] L. H. Kashkool, "Optimization of Machining Parameters of AISI 1045 Steel for Better Surface Finish and Tool Life Using TiN Coated Carbide Insert," Tikrit J. Eng. Sci., vol. 29, no. 2, pp. 1–6, 2022. doi:10.25130/tjes.29.2.1
  • [14] E. Akdeniz and H. Arslan, “A new design of boring bar using TiNi3 alloy to reduce vibration in turning operations,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 237, no. 1-2, 2023, pp.105-121. doi:10.1177/0954405 4221104607
There are 14 citations in total.

Details

Primary Language Turkish
Subjects Mechanical Engineering
Journal Section Research Articles
Authors

Eymen Akdeniz 0000-0003-0169-4422

Mustafa Bozdemir 0000-0002-9332-2054

Muhammet Yılmaz 0000-0002-1068-8828

Mehmet Kutay Gezer This is me 0000-0003-2897-6198

Publication Date January 1, 2024
Submission Date May 9, 2023
Acceptance Date September 4, 2023
Published in Issue Year 2023 Volume: 9 Issue: 3

Cite

IEEE E. Akdeniz, M. Bozdemir, M. Yılmaz, and M. K. Gezer, “AL 7075-T6 Frezeleme Operasyonunda Kesme Parametrelerinin Ve Takım Tutucunun Yüzey Pürüzlülüğüne Ve İşleme Hassasiyetine Etkisinin İncelenmesi”, GJES, vol. 9, no. 3, pp. 535–543, 2024.

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