The Optimization of Cutting Parameters Using Taguchi Method in Milling of Tempered Aluminum 5754 Alloy

Year 2019, Volume: 7 Issue: 1, 45 - 60, 31.01.2019

Gürcan Samtaş , Salih Korucu

https://doi.org/10.29130/dubited.423795

Cited By: 5

Abstract

Aluminum alloys have been widely used in plastic injection molds in the automotive and aerospace industries due to their high strength and weight ratio, and good corrosion and fatigue resistance. In this study, 5754-H111 tempered aluminum alloy piece with 80x80x30 mm dimensions was machined with face milling operation using coated and uncoated inserts. The effects of cutting parameters on surface roughness during face milling were investigated. In the experiments, different inserts (uncoated, Al2O3-TiCN-TiN coated, TiAlN Nano coated), cutting speeds (250, 350, 550 m/min), feed rates (0.1, 0.2, 0.35 mm/tooth) and cutting depths (1, 1.5, 2 mm) — each having three conditions — were used with the Taguchi L27 orthogonal array. The values obtained at the end of the experiments were evaluated using signal-to-noise ratio (S/N), variance analysis (ANOVA), three-dimensional
graphs, and regression analyses. The minimum surface roughness was obtained using the uncoated insert at 1 mm
cutting depth, 350 m/min cutting speed and 0.35 mm/tooth feed rate. The surface roughness values for these cutting
conditions were found as 0.26 μm in the calculations and measured as 0.29 μm in the verification experiments.

Keywords

AA 5754, Surface roughness, Face milling, Taguchi method, Optimization

Temperlenmiş Alüminyum 5754 Alaşımının Frezelenmesinde Kesme Parametrelerinin Taguchi Metodu Kullanılarak Optimizasyonu

Abstract

Alüminyum alaşımları günümüzde, yüksek dayanım ve ağırlık oranı, iyi korozyon ve yorulma direnci nedeniyle,
otomotiv ve havacılık sanayinde, plastik enjeksiyon kalıplarında yaygın bir şekilde kullanılmaktadır. Bu
çalışmada, 80x80x30 mm ebatlarında 5754-H111 temperlenmiş alüminyumun alaşımına, kaplamalı ve kaplamasız
kesici uçlarla yüzey frezeleme işlemi uygulanmış ve yüzey frezeleme işlemi esnasında kesme parametrelerinin
yüzey pürüzlülüğü üzerindeki etkileri araştırılmıştır. Deneylerde Taguchi L27 ortogonal dizini ile üç faklı kesici uç
(Kaplamasız, Al2O3-TiCN-TiN kaplamalı, TiAlN Nano kaplamalı), kesme hızı (250, 350, 550 m/dak), ilerleme
oranı (0.1, 0.2, 0.35 mm/diş) ve üç faklı kesme derinliği (1, 1.5, 2 mm) kullanılmıştır. Deneyler sonunda elde
edilen değerler, sinyal-gürültü oranı (S/N), varyans analizi (ANOVA), üç boyutlu grafikler ve regresyon metodu
kullanılarak değerlendirilmiştir. Deneylerden sonra en düşük yüzey pürüzlülüğü; kaplamasız kesici uç, 1 mm
kesme derinliği, 350 m/dak kesme hızı ve 0.35 mm/diş ilerleme oranında elde edilmiştir. Bu kesme şartları için
yüzey pürüzlülük değerleri hesaplamalarda 0.26 µm olarak bulunmuş, doğrulama deneylerinde 0.29 µm olarak
ölçülmüştür.

Keywords

AA 5754, Yüzey pürüzlülüğü, Yüzey frezeleme, Taguchi metodu, Optimizasyon

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