Investigation of the Effects of DLC Cutting Tool and Machining Parameters on Surface Quality and Cutting Force

Abstract

In this study, the surface roughness and cutting forces of Al 7075 alloy were investigated experimentally while milling with cutting tool coated by Diamond-Like-Carbon (DLC). The influence of feed, cutting speed and depth of cut on surface roughness and cutting forces was analysed. Taguchi technique was used when designing the experiment. With this way, the time and cost of the experiments economised, and the data found from the experimental outcomes were adjusted, and improvement was performed. The connection between the dependent and independent variables was modelled mathematically by regression analysis method. As a result, the most effective factor in the formation of surface roughness with ANOVA was the feed with 92.46%, the most effective factor in the creation of cutting force was the depth of cut with 82.91 %. With the regression analysis, Ra's predictive equation was obtained with an accuracy of 94.7%, and the force estimation of the equation with 87.1% accuracy. In this study where the Taguchi method has been applied, the processing methods such as cutting force and surface roughness have been minimized, the performance has been increased, and the product quality has been improved.

Keywords

• DLC coated tools,Aluminium 7075,Taguchi,Regression Analysis,Variance Analysis (ANOVA)

DLC Kesici Takım ve İşleme Parametrelerinin Yüzey Kalitesine ve Kesme Kuvvetlerine Etkilerinin İncelenmesi

Öz

Bu çalışmada, Al 7075 alaşımın Diamond Like Carbon (DLC) kaplamalı kesici takımlarla frezelemede yüzey pürüzlülüğü ve kesme kuvvetleri deneysel olarak incelenmiştir. İlerleme, devir ve talaş derinliğinin yüzey pürüzlülüğüne ve kesme kuvvetlerine etkisi araştırılmıştır. Deney tasarımında Taguchi metodu kullanılmıştır. Bu yöntem ile deneylere sarfadilecek zaman ve maliyetten tasarruf edilmiş, deney neticelerinde elde edilen veriler optimize edilerek iyileştirme gerçekleştirilmiştir. Bağımlı ve bağımsız değişkenler arasındaki ilişki matematiksel olarak regresyon analiz yöntemiyle modellenmiştir. Sonuç olarak da ANOVA ile de yüzeydeki pürüzlülüğün oluşumunda en etkili faktör % 92.46 ile ilerleme, kesme kuvveti oluşumunda en etkili faktör % 82.91 ile talaş derinliği olduğu anlaşılmıştır.  Regresyon analizi ile de Ra tahminsel denklemi % 94.7 doğruluk ile,  kuvvet tahminsel denklemi % 87.1 doğruluk ile elde edilmiştir. Taguchi metodunun uygulandığı bu çalışmada kesme kuvveti ve yüzey pürüzlülüğü gibi işleme yöntemlerinde en aza indirilip, performans yükseltilmiş ve elde edilen ürün kalitesi iyileştirilmiştir.

Anahtar Kelimeler

• DLC kaplı takımlar,Alüminyum 7075,Taguchi,Regrasyon Analizi,Varyans Analizi (ANOVA)

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