Deep Rolling of Al6061-T6 Material and Performance Evaluation with New Type Designed WNMG Formed Rolling Tool

Abstract

In deep rolling, ball and roller type burnishing tools are generally used. It is generally difficult to deep roll contours with curved and conical shapes with the existing rolling tools. The aim of this study is to design experiments with a roller insert that will be an alternative to deep rolling inserts being used now and that can be fixed on the present tool holders; and to investigate the usability of them including curve and conical formed workpieces with the help of this designed tool. For this purpose, a spherical insert with a radius of 1 mm in the form of WNMG was designed based on the WNMG insert model and used in deep rolling of Al6061-T6 material using different forms and parameters. 143, 330, 495 N rolling force, 0.04, 0.08, 0.12 mm/rev feed and 400, 600, 800 rpm spindle speed were selected as rolling parameters. By examining the microhardness and surface structure of deep-rolled Al6061 parts, the achievability of the results of existing tools in deep rolling was investigated. At the end of the study, it was determined that the new type of rolling tool produced results similar to the existing tools in deep rolling in terms of microhardness and surface morphology, which enabled that the workpieces with curve and conical forms could also be rolled, and that this rolling tool could be used as an alternative in deep rolling.

Keywords

• Al6061
• deep rolling
• microhardness
• surface roughness
• tribology

Supporting Institution

Batman Üniversity

Project Number

BTÜBAP-2022-YL-05

Ethical Statement

There are no ethical issues after the publication of this manuscript.

Thanks

In order to carry out the research, Batman University unit of BAP (Scientific Research Projects) provided financial support to this study numbered BTUBAP-2022-YL-05.

Yeni Tip Tasarlanan WNMG Formlu Haddeleme Takımı ile Al6061-T6 Malzemenin Derin Haddelenmesi ve Performans Değerlendirmesi

Abstract

Derin haddelemede genel olarak bilyeli ve makaralı tip ezici uçlar kullanılmaktadır. Ayrıca mevcut haddeleme takımları ile çoğunlukla eğrisel ve konik forma sahip kontürlerin derin haddelenmesi zordur. Bu çalışmada amaç, kullanılan ezici uçlara alternatif olacak ve mevcut takım tutuculara monte edilebilen bir ezici uç tasarımı yapmak ve tasarlanan bu takımla eğrisel ve konik formlu parçalar da dahil olmak üzere derin haddelemede kullanılabilirliğini araştırmaktır. Bu amaçla WNMG insert uç modeli baz alınarak WNMG formunda 1 mm radüslü küresel uca sahip ezici tip uç tasarlanmış ve farklı form ve parametreler kullanılarak Al6061-T6 malzemenin derin haddelemesinde kullanılmıştır. İşlem parametreleri olarak 143, 330, 495 N haddeleme kuvveti, 0.04, 0.08, 0.12 mm/dev ilerleme ve 400, 600, 800 dev/dak devir sayısı seçilmiştir. Derin haddelenmiş Al6061 parçalardaki mikrosertlik ve yüzey yapısı incelenerek mevcut takımların derin haddelemedeki sonuçlarının elde edilebilirliği araştırılmıştır. Çalışma sonunda yeni tip ezici takımın mikrosertlik ve yüzey morfolojisi açısından derin haddelemedeki mevcut takımlara benzer sonuçlar ürettiği, eğrisel ve konik formlara sahip parçaların da haddelenebildiği ve bu ezici takımın derin haddelemede alternatif olarak kullanılabileceği tespit edilmiştir.

Project Number

BTÜBAP-2022-YL-05

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