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AISI 304 Paslanmaz Döküm Çeliğinin Frezelemesinde İşleme Şartlarının Yüzey Pürüzlülüğü ve Çapak Oluşumuna Etkisi

Year 2022, Volume: 8 Issue: 1, 49 - 59, 30.04.2022

Abstract

AISI 304 kalite paslanmaz çelikler yüksek mekanik özelliklere ve yüksek korozyon direncine sahip olduklarından oldukça yaygın kullanılan bir paslanmaz çelik çeşididir. Karmaşık ve büyük ebatlara sahip paslanmaz parçalar döküm yöntemi ile üretilmektedir. Döküm ile üretilen paslanmaz çeliklerin işlenebilirliği dövme yöntemlerine göre daha da zor olmaktadır. Bu çalışmada, AISI 304 paslanmaz döküm çeliğinin frezelenmesinde kuru ve buharlı soğuk hava şartlarında üç farklı kesme hızı, üç farklı ilerleme miktarı ve sabit kesme derinliğinin yüzey pürüzlülüğü ve çapak oluşumuna etkisi araştırılmıştır. Sonuç olarak buharlı soğuk hava (BSH) ile işlemede elde edilen yüzey pürüzlülüklerinde kuru işleme şartlarına göre %15-%48 arasında bir iyileşme sağlanmıştır. Her iki kesme şartında, ilerleme miktarı çapak yüksekliğini artırırken kesme hızının artışı çapak yüksekliğini azaltmıştır. BSH uygulaması çapak yüksekliğinin ortalama %9 azalmasını sağlamıştır.

References

  • J. Kopac and S. Sali, “Tool wear monitoring during the turning process” Journal of Materials Processing Technology, vol.113, pp. 312–316, June 2001. https://doi.org/10.1016/S0924-0136(01)00621-5
  • M. Günay, “AISI 316L çeliğinin işlenmesinde takım radyüsü ve kesme parametrelerinin Taguchi yöntemiyle optimizasyonu” Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, vol 28 (3), pp. 437-444, 2013.
  • J.W. Sutherland, V.N. Kulur, N.C. King and B.F. von Turkovich, “An experimental investigation of air quality in wet and dry turning” CIRP Annals, vol. 49(1), pp. 61-64, 2000. https://doi.org/10.1016/S0007-8506(07)62896-0.
  • P.S Sreejith and B.K.A Ngoi, “Dry machining: Machining of the future” Journal of Materials Processing Technology, vol 101(1–3), pp. 287-29, 2000. https://doi.org/10.1016/S0924-0136(00)00445-3.
  • M.Y. Noordin, V.C. Venkatesh, C.L. Chan and A. Abdullah, “Performance evaluation of cemented carbide tools in turning AISI 1010 steel” Journal of Materials Processing Technology, vol. 116(1), pp.16-21, 2001. https://doi.org/10.1016/S0924-0136(01)00838-X.
  • D. O’Sullivan and M. Cotterell, “Machinability of austenitic stainless steel SS303” Journal of Materials Processing Technology, vol. 124(1–2,), pp. 153-159, 2002. https://doi.org/10.1016/S0924-0136(02)00197-8.
  • E. Ezugwu, and S.K. Kim, “The performance of cermet cutting tools when machining an Ni–Cr–Mo (En 24) steel” Lubrication Engineering, vol. 51(2), pp.139–145, 1995.
  • M. Rahman, A. Senthil Kumar and M.U. Salam, “Experimental evaluation on the effect of minimal quantities of lubricant in milling” International Journal of Machine Tools and Manufacture, vol. 42 (5), pp. 539-547, 2002. https://doi.org/10.1016/S0890-6955(01)00160-2.
  • W.Y.H. Liew, “Low-speed milling of stainless steel wih TiAlN single-layer and TiAlN/AlCrN nano-multilayer coated carbide tools under different lubrication conditions” Wear, vol. 269, pp. 617-631, 2010. https://doi.org/10.1016/j.wear.2010.06.012
  • T. Braham-Bouchnak, G. Germain, P. Robert and J.L. Lebrun, “High pressure water jet assisted machining of duplex steel: machinability and tool life” International Journal of Material Forming, 3(1), pp.507–510, 2010.
  • P. Chockalingam and L.H. Wee, “Surface roughness and tool wear study on milling of aısı 304 stainless steel using different cooling conditions” International Journal of Engineering and Technology, vol. 2(8), pp. 1386-1391, August 2012.
  • E. Şirin and Ş. Şirin, “Investigation of the performance of ecological cooling/lubrication methods in the milling of AISI 316L stainless steel” İmalat Teknolojileri ve Uygulamaları, vol. 2(1), pp. 75-84, 2021.
  • Ç. V. Yıldırım, “Grafit parçacık takviyeli nano akışkan kullanılarak AISI 316’nın frezelenmesinde yüzey pürüzlülüğü ve kesme sıcaklığının optimizasyonu” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, vol. 7, pp. 326-341, 2019.
  • E. Kuram, “AISI 304 paslanmaz çeliğinin frezelenmesinde farklı kaplama malzemelerinin takım aşınmasına, kesme kuvvetlerine ve yüzey pürüzlülüğüne etkileri” Politeknik Dergisi, vol.19 (4), pp. 433-443, 2016.
  • E. Altınkaya and A. Güllü, “AISI 316 östenitik paslanmaz çeliğin işlenmesinde kesme hızının ve takım kaplamasının takım aşınmasına etkileri” Politeknik Dergisi, vol.11(3), pp. 243-247, 2008.
  • R. Çakıroğlu and G. Uzun “Yüksek ilerleme ile frezeleme işlemi esnasinda oluşan kesme kuvvetinin ve iş parçasi yüzey pürüzlülüğünün yapay sinir ağlari ile modellenmesi” Gazi Mühendislik Bilimleri Dergisi, vol. 7(1), pp. 58-66, 2021.
  • S.Y. Jin, A. Pramanik, A.K. Basak, A.K. C. Prakash, S. Shankar and S. Debnath “Burr formation and its treatments—a review” The International Journal of Advanced Manufacturing Technology, vol 107, pp. 2189–2210, 2020. https://doi.org/10.1007/s00170-020-05203-2
  • J.C. Aurich, D. Dornfeld, P.J. Arrazola, V. Franke, L. Leitz and S. Min, “Burrs-analysis, control and removal, CIRP Annals, vol. 58(2), pp. 519-542, 2009, https://doi.org/10.1016/j.cirp.2009.09.004.
  • L.C. da Silva, P.R. da Mota, M.B. da Silva, M.B. W.F. Sales, A.R. Machado and M.J. Jackson, “Burr height minimization using the response surface methodology in milling of PH 13-8 Mo stainless steel” The International Journal of Advanced Manufacturing Technology, vol. 87, pp. 3485–3496, 2016. https://doi.org/10.1007/s00170-016-8747-5
  • T.R. Lin, “Experimental study of burr formation and tool chipping in the face milling of stainless steel” Journal of Materials Processing Technology, vol. 108, pp. 12-20, 2000. https://doi.org/10.1016/S0924-0136(00)00573-2.
  • L.C. da Silva, P.R. da Mota, M.B. da Silva, E.O. Ezugwu and A.R. Machado, “Study of burr behavior in face milling of PH 13-8 Mo stainless steel” CIRP Journal of Manufacturing Science and Technology, vol.8, pp. 34-42, 2015. https://doi.org/10.1016/j.cirpj.2014.10.003.
  • P.P. Saha, S. Das, “Minimization of exit burr in face milling of medium carbon steel by exit edge beveling” Production Engineering Research and Development, vol. 8, pp. 469–476, 2014. Doi: 10.1007/s11740-014-0550-2.
  • U. Heisel, M. Schaal, G. Wolf, “Burr Formation in milling with minimum quantity lubrication” Production Engineering Research and Development, vol. 3 (1), pp. 23-30, 2009. Doi: 10.1007/s11740-008-0138-9.
  • Uzun G. and R. Çakıroğlu, “Yüksek ilerlemeli frezeleme işleminde işlenebilirlik parametrelerinin incelenmesi” İmalat Teknolojileri ve Uygulamaları, vol. 1(1), pp. 34-41, 2020.
  • G. Liu, B. Zou, C. Huang, X. Wang, J. Wang and Z. Liu, “Tool damage and its effect on the machined surface roughness in high-speed face milling the 17-4PH stainless steel” The International Journal of Advanced Manufacturing Technology, vol. 83, pp. 257–264, 2016. Doi: 10.1007/s00170-015-7564-6
  • C.C. Chen, N.M. Liu, K.T. Chiang and H.L. Chen, “Experimental investigation of tool vibration and surface roughness in the precision end-milling process using the singular spectrum analysis” The International Journal of Advanced Manufacturing Technology, vol. 63, pp. 797-815, 2012. Doi: 10.1007/s00170-012-3943-4
  • G. Singh, M.K. Gupta, H. Hegab, A.M. Khan, Q. Song, Z. Liu, M. Mia, M. Jamil, V.S. Sharma, M. Sarikaya and C.I. Pruncu, “Progress for sustainability in the mist assisted cooling techniques: a critical review” The International Journal of Advanced Manufacturing Technology, vol.109, pp. 345–376, 2020. https://doi.org/10.1007/s00170-020-05529-x
  • A. Çetin, “Çelik döküm parçalarda kalıntı (inklüzyon) kaynakları” Available: https://dokumhane.net/kutuphane/celik-dokum-parcalarda-kalinti-inkluzyon-kaynaklari/. [Accessed: Oct. 25, 2021].
  • S. Hajiahmadi, “Burr size investigation in micro milling of stainless steel 316L” International Journal of Lightweight Materials and Manufacture, vol. 2, pp. 296-304, 2019.

The Effect of Machining Conditions on Surface Roughness and Burr Formation in Milling of AISI 304 Cast Stainless Steel

Year 2022, Volume: 8 Issue: 1, 49 - 59, 30.04.2022

Abstract

AISI 304 quality stainless steels are a very common type of stainless steel because they have high mechanical properties and high corrosion resistance. Stainless parts with complex and large dimensions are produced by the casting method. The machinability of stainless steels produced by casting is even more difficult than forging methods. In this study, the effects of three different cutting speeds, feed rates and constant cutting depth on the surface roughness and burr formation in dry and mist cold air (MCA) conditions were investigated in milling of AISI 304 stainless cast steel. As a result, an improvement between 15% and 48% was achieved in the average surface roughness (Ra) obtained in machining with MCA compared to dry machining conditions. In both cutting conditions, the increasing feed rate increased the burr height, while the increase in cutting speed decreased the burr height. MCA application provided an average of 9% reduction in burr height.

References

  • J. Kopac and S. Sali, “Tool wear monitoring during the turning process” Journal of Materials Processing Technology, vol.113, pp. 312–316, June 2001. https://doi.org/10.1016/S0924-0136(01)00621-5
  • M. Günay, “AISI 316L çeliğinin işlenmesinde takım radyüsü ve kesme parametrelerinin Taguchi yöntemiyle optimizasyonu” Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, vol 28 (3), pp. 437-444, 2013.
  • J.W. Sutherland, V.N. Kulur, N.C. King and B.F. von Turkovich, “An experimental investigation of air quality in wet and dry turning” CIRP Annals, vol. 49(1), pp. 61-64, 2000. https://doi.org/10.1016/S0007-8506(07)62896-0.
  • P.S Sreejith and B.K.A Ngoi, “Dry machining: Machining of the future” Journal of Materials Processing Technology, vol 101(1–3), pp. 287-29, 2000. https://doi.org/10.1016/S0924-0136(00)00445-3.
  • M.Y. Noordin, V.C. Venkatesh, C.L. Chan and A. Abdullah, “Performance evaluation of cemented carbide tools in turning AISI 1010 steel” Journal of Materials Processing Technology, vol. 116(1), pp.16-21, 2001. https://doi.org/10.1016/S0924-0136(01)00838-X.
  • D. O’Sullivan and M. Cotterell, “Machinability of austenitic stainless steel SS303” Journal of Materials Processing Technology, vol. 124(1–2,), pp. 153-159, 2002. https://doi.org/10.1016/S0924-0136(02)00197-8.
  • E. Ezugwu, and S.K. Kim, “The performance of cermet cutting tools when machining an Ni–Cr–Mo (En 24) steel” Lubrication Engineering, vol. 51(2), pp.139–145, 1995.
  • M. Rahman, A. Senthil Kumar and M.U. Salam, “Experimental evaluation on the effect of minimal quantities of lubricant in milling” International Journal of Machine Tools and Manufacture, vol. 42 (5), pp. 539-547, 2002. https://doi.org/10.1016/S0890-6955(01)00160-2.
  • W.Y.H. Liew, “Low-speed milling of stainless steel wih TiAlN single-layer and TiAlN/AlCrN nano-multilayer coated carbide tools under different lubrication conditions” Wear, vol. 269, pp. 617-631, 2010. https://doi.org/10.1016/j.wear.2010.06.012
  • T. Braham-Bouchnak, G. Germain, P. Robert and J.L. Lebrun, “High pressure water jet assisted machining of duplex steel: machinability and tool life” International Journal of Material Forming, 3(1), pp.507–510, 2010.
  • P. Chockalingam and L.H. Wee, “Surface roughness and tool wear study on milling of aısı 304 stainless steel using different cooling conditions” International Journal of Engineering and Technology, vol. 2(8), pp. 1386-1391, August 2012.
  • E. Şirin and Ş. Şirin, “Investigation of the performance of ecological cooling/lubrication methods in the milling of AISI 316L stainless steel” İmalat Teknolojileri ve Uygulamaları, vol. 2(1), pp. 75-84, 2021.
  • Ç. V. Yıldırım, “Grafit parçacık takviyeli nano akışkan kullanılarak AISI 316’nın frezelenmesinde yüzey pürüzlülüğü ve kesme sıcaklığının optimizasyonu” Düzce Üniversitesi Bilim ve Teknoloji Dergisi, vol. 7, pp. 326-341, 2019.
  • E. Kuram, “AISI 304 paslanmaz çeliğinin frezelenmesinde farklı kaplama malzemelerinin takım aşınmasına, kesme kuvvetlerine ve yüzey pürüzlülüğüne etkileri” Politeknik Dergisi, vol.19 (4), pp. 433-443, 2016.
  • E. Altınkaya and A. Güllü, “AISI 316 östenitik paslanmaz çeliğin işlenmesinde kesme hızının ve takım kaplamasının takım aşınmasına etkileri” Politeknik Dergisi, vol.11(3), pp. 243-247, 2008.
  • R. Çakıroğlu and G. Uzun “Yüksek ilerleme ile frezeleme işlemi esnasinda oluşan kesme kuvvetinin ve iş parçasi yüzey pürüzlülüğünün yapay sinir ağlari ile modellenmesi” Gazi Mühendislik Bilimleri Dergisi, vol. 7(1), pp. 58-66, 2021.
  • S.Y. Jin, A. Pramanik, A.K. Basak, A.K. C. Prakash, S. Shankar and S. Debnath “Burr formation and its treatments—a review” The International Journal of Advanced Manufacturing Technology, vol 107, pp. 2189–2210, 2020. https://doi.org/10.1007/s00170-020-05203-2
  • J.C. Aurich, D. Dornfeld, P.J. Arrazola, V. Franke, L. Leitz and S. Min, “Burrs-analysis, control and removal, CIRP Annals, vol. 58(2), pp. 519-542, 2009, https://doi.org/10.1016/j.cirp.2009.09.004.
  • L.C. da Silva, P.R. da Mota, M.B. da Silva, M.B. W.F. Sales, A.R. Machado and M.J. Jackson, “Burr height minimization using the response surface methodology in milling of PH 13-8 Mo stainless steel” The International Journal of Advanced Manufacturing Technology, vol. 87, pp. 3485–3496, 2016. https://doi.org/10.1007/s00170-016-8747-5
  • T.R. Lin, “Experimental study of burr formation and tool chipping in the face milling of stainless steel” Journal of Materials Processing Technology, vol. 108, pp. 12-20, 2000. https://doi.org/10.1016/S0924-0136(00)00573-2.
  • L.C. da Silva, P.R. da Mota, M.B. da Silva, E.O. Ezugwu and A.R. Machado, “Study of burr behavior in face milling of PH 13-8 Mo stainless steel” CIRP Journal of Manufacturing Science and Technology, vol.8, pp. 34-42, 2015. https://doi.org/10.1016/j.cirpj.2014.10.003.
  • P.P. Saha, S. Das, “Minimization of exit burr in face milling of medium carbon steel by exit edge beveling” Production Engineering Research and Development, vol. 8, pp. 469–476, 2014. Doi: 10.1007/s11740-014-0550-2.
  • U. Heisel, M. Schaal, G. Wolf, “Burr Formation in milling with minimum quantity lubrication” Production Engineering Research and Development, vol. 3 (1), pp. 23-30, 2009. Doi: 10.1007/s11740-008-0138-9.
  • Uzun G. and R. Çakıroğlu, “Yüksek ilerlemeli frezeleme işleminde işlenebilirlik parametrelerinin incelenmesi” İmalat Teknolojileri ve Uygulamaları, vol. 1(1), pp. 34-41, 2020.
  • G. Liu, B. Zou, C. Huang, X. Wang, J. Wang and Z. Liu, “Tool damage and its effect on the machined surface roughness in high-speed face milling the 17-4PH stainless steel” The International Journal of Advanced Manufacturing Technology, vol. 83, pp. 257–264, 2016. Doi: 10.1007/s00170-015-7564-6
  • C.C. Chen, N.M. Liu, K.T. Chiang and H.L. Chen, “Experimental investigation of tool vibration and surface roughness in the precision end-milling process using the singular spectrum analysis” The International Journal of Advanced Manufacturing Technology, vol. 63, pp. 797-815, 2012. Doi: 10.1007/s00170-012-3943-4
  • G. Singh, M.K. Gupta, H. Hegab, A.M. Khan, Q. Song, Z. Liu, M. Mia, M. Jamil, V.S. Sharma, M. Sarikaya and C.I. Pruncu, “Progress for sustainability in the mist assisted cooling techniques: a critical review” The International Journal of Advanced Manufacturing Technology, vol.109, pp. 345–376, 2020. https://doi.org/10.1007/s00170-020-05529-x
  • A. Çetin, “Çelik döküm parçalarda kalıntı (inklüzyon) kaynakları” Available: https://dokumhane.net/kutuphane/celik-dokum-parcalarda-kalinti-inkluzyon-kaynaklari/. [Accessed: Oct. 25, 2021].
  • S. Hajiahmadi, “Burr size investigation in micro milling of stainless steel 316L” International Journal of Lightweight Materials and Manufacture, vol. 2, pp. 296-304, 2019.
There are 29 citations in total.

Details

Primary Language English
Subjects Mechanical Engineering
Journal Section Research Articles
Authors

Mehmet Boy 0000-0003-2471-8001

Mürsel Avci This is me 0000-0002-1808-0438

Publication Date April 30, 2022
Submission Date October 27, 2021
Acceptance Date January 22, 2022
Published in Issue Year 2022 Volume: 8 Issue: 1

Cite

IEEE M. Boy and M. Avci, “The Effect of Machining Conditions on Surface Roughness and Burr Formation in Milling of AISI 304 Cast Stainless Steel”, GJES, vol. 8, no. 1, pp. 49–59, 2022.

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