Effect of Processing Parameters on Surface Integrity

Year 2019, Volume: 3 Issue: 1, 16 - 20, 15.07.2019

Mustafa Ay , Ayhan Etyemez

Abstract

In this study, the surface roughness of PMD 23 cold work tool steel in milling with multi-layer TiAlN coated cutting tools was experimentally investigated. The effect of surface roughness on the rotation, feed ratio, and MQL flow rate was investigated. The Taguchi technique was used to optimize the milling process. Also, variance analysis (ANOVA) was used to determine the effect of each parameter on the obtained results. Finally, the relationship between dependent variables and independent variables was modeled by regression analysis. In this study, the optimal machinability of PMD 23 cold work tool steel with multi-layer TiAlN coating was determined.

Keywords

ANOVA, MQL, PM23, Surface integrity, Taguchi

Supporting Institution

BAPKO of Marmara University

Project Number

FEN-E090517-0273

References

• [1] Law KMY, Geddam A, Ostafiev VA. A Process-Design Approach to Error Compensation in the End Milling of Pockets. Journal of Materials Processing Technology (1999) 89-90:238–244. doi:10.1016/S0924-0136(99)00031-X.
• [2] Toh CK. A Study of the Effects of Cutter Path Strategies and Orientations in Milling. Journal of Materials Processing Technology (2004) 152(3):346–356. doi:10.1016/j.jmatprotec.2004.04.382.
• [3] Omirou SL, Nearchou AC. An Epitrochoidal Pocket: A New Canned Cycle for CNC Milling Machines. Robotics and Computer-Integrated Manufacturing (2009) 25(1):73–80. doi:10.1016/j.rcim.2007.09.003.
• [4] Pateloup V, Duc E, Ray P. Corner Optimization for Pocket Machining. International Journal of Machine Tools and Manufacture (2004) 44(12-13):1343–1353. doi:10.1016/j.ijmachtools.2004.04.011.
• [5] Hinds BK, Ong TS. End Milling of Circular Pockets to Meet Geometric Tolerances. Journal of Materials Processing Technology (2004) 152(3):339–345. doi:10.1016/j.jmatprotec.2004.04.375.
• [6] Nurul Amin AKM, Dolah SB, Mahmud MB, Lajis MA. Effects of Workpiece Preheating on Surface Roughness, Chatter and Tool Performance During End Milling of Hardened Steel D2. Journal of Materials Processing Technology (2008) 201(1-3):466–470. doi:10.1016/j.jmatprotec.2007.11.304.
• [7] Brandão LC, Coelho RT, Rodrigues AR. Experimental and Theoretical Study of Workpiece Temperature When End Milling Hardened Steels Using (TiAl)N-coated and PcBN-tipped Tools. Journal of Materials Processing Technology (2008) 199(1-3):234–244. doi:10.1016/j.jmatprotec.2007.07.049.
• [8] Chung-Chen T, Hong H. Comparison of the Tool Life of Tungsten Carbides Coated by Multi-layer TiCN and TiAlCN for End Mills Using the Taguchi Method. Journal of Materials Processing Technology (2002) 123(1):1–4. doi:10.1016/S0924-0136(01)01152-9.
• [9] Ghani JA, Choudhury IA, Masjuki HH. Performance of P10 TiN Coated Carbide Tools When End Milling AISI H13 Tool Steel at High Cutting Speed. Journal of Materials Processing Technology (2004) 153-154:1062–1066. doi:10.1016/j.jmatprotec.2004.04.353.
• [10] Bozdoğan M. CNC Freze Tezgahında Havuz İşlemede Takım Yolu ve Kesme Parametrelerinin Yüzey Kalitesine Etkilerinin İncelenmesi [Investigation of the Effects of Tool Path and Cutting Parameters on Surface Quality in Pool Processing in CNC Milling Machine]. Master Thesis. Marmara University. İstanbul (2012).
• [11] Abou-El-Hossein KA, Kadirgama K, Hamdi M, Benyounis KY. Prediction of Cutting Force in End-Milling Operation of Modified AISI P20 Tool Steel. Journal of Materials Processing Technology (2007) 182(1-3):241–247. doi:10.1016/j.jmatprotec.2006.07.037.
• [12] Coldwell H, Woods R, Paul M, Koshy P, Dewes R, Aspinwall D. Rapid Machining of Hardened AISI H13 and D2 Moulds, Dies and Press Tools. Journal of Materials Processing Technology (2003) 135(2-3):301–311. doi:10.1016/S0924-0136(02)00861-0.
• [13] Gologlu C, Sakarya N. The Effects of Cutter Path Strategies on Surface Roughness of Pocket Milling of 1.2738 Steel Based on Taguchi Method. Journal of Materials Processing Technology (2008) 206(1-3):7–15. doi:10.1016/j.jmatprotec.2007.11.300.
• [14] Ay M, Karagol T. Investigation of the Machinability of the Al 7075 Alloy Using DLC Coated Cutting Tools. Scientific Research and Essays (2011) 6(1):44–51.
• [15] Ay M, Turhan A. Determination and Optimization of the Effect of Cutting Parameters and Workpiece Length on the Geometric Tolerances and Surface Roughness in Turning Operation. International Journal of Physical Sciences (2011) 6(5):1074–1084. doi:10.5897/IJPS11.130.
• [16] Ay M, Altunpak Y. Optimization of Cutting Parameters and Graphite Rate in Drilling of a Hybrid Aluminium Matrix Composites. The Journal of Engineering and Fundamentals (2015) 2(2):42–50. doi:10.17530/jef.15.17.2.2.
• [17] Ay M, Ay İ. The Prediction and Optimization of the Effects of Abrasive Waterjet Cutting Parameters On Kerf. Acta Physica Polonica A (2016) 129(4):762–766. doi:10.12693/APhysPolA.129.762.