Talaşlı imalatta nano-akışkan kullanımının soğutmaya etkilerinin deneysel olarak araştırılması

Abstract

Nano-akışkanların talaşlı imalat süreçlerinde kullanımı, gelişmiş termo-fiziksel özellikleri sayesinde giderek daha yaygın hale gelmektedir. Önceki çalışmalar; Al2O3, MWCNT veya TiO2 gibi nano-parçacıkların, temel akışkanlara eklenmesinin yoğunluk, viskozite ve ısıl iletkenlik gibi özelikleri iyileştirdiğini göstermektedir. Bu deneysel çalışma; söz konusu nano-parçacıkların %0.5, %1 ve %1.5 oranlarında bor yağı–su karışımına eklenmesinin etkisini incelemektedir. Araştırma üç ana aşamada gerçekleştirilmiştir: Nano-akışkan hazırlanması, termo-fiziksel özeliklerin değerlendirilmesi ve Ti-6Al-4V alaşımı kullanılarak yapılan talaşlı imalat deneyleri. Sonuçlar, 24.5 °C’da nano-parçacık derişikliğinin artmasının akışkan yoğunluğunda sürekli bir artışa yol açtığını ortaya koymuştur. Ancak, dinamik viskozite ve ısıl iletkenlik için benzer bir artış gözlemlenmemiş; bu özelikler, %1’in üzerindeki derişikliklerde azalmaya başlamıştır. Bu azalma, çökelme ve tortulaşma gibi akışkan kararsızlığı problemlerine bağlanmıştır. Ayrıca; nano-akışkan kullanımı, takım–iş parçası ara-yüzeyindeki sıcaklığı önemli ölçüde düşürmüştür. Örneğin, %0.5 oranında MWCNT parçacığı kullanımı bu sıcaklığı yaklaşık %18 oranında azaltmıştır. Diğer taraftan; daha yüksek derişiklikler, parçacık birikimi nedeniyle ara-yüzey sıcaklığında artışa ve yüzey pürüzlülüğünde kötüleşmeye neden olmuştur. Özellikle %0.5 MWCNT kullanımı, yüzey kalitesinde yaklaşık %25’lik bir iyileşme sağlamıştır. Bu çalışma; talaşlı imalat performansının yalnızca optimum nano-parçacık derişikliklerinde iyileştirilebildiğini; aşırı miktarda nano-parçacık kullanımının performansı düşürdüğünü ve bu bulgunun kesici uçların SEM analizleriyle desteklendiğini ortaya koymuştur.

Keywords

• Bor mineral yağı-su karışımı
• Nano-akışkan
• Termofiziksel özelik
• Yüzey pürüzlülüğü
• Talaşlı imalat

Experimental investigation of effects of nano-fluid usage on cooling in machining

Abstract

Application of nano-fluids in machining processes is becoming increasingly common due to their enhanced thermo-physical characteristics. Previous studies indicate that adding nano-particles such as Al2O3, MWCNT, or TiO2 into base fluids improves properties like density, viscosity, and thermal conductivity. This experimental study investigates the impact of addition of these nano-particles at concentrations of 0.5%, 1%, and 1.5% into a boron oil–water mixture. The research was carried out in three main phases: Nano-fluid preparation, thermo-physical property evaluation, and machining experiments on Ti-6Al-4V alloy. The results showed that increasing the nano-particle concentration led to a consistent rise in fluid density at 24.5 °C. However, similar trends were not observed for dynamic viscosity and thermal conductivity, which began to decline beyond 1% concentration of nano-particles. This decrease was attributed to fluid instability issues like precipitation and sedimentation. Furthermore, the use of nano-fluids significantly marked down temperature at the tool–workpiece interface. For instance, a 0.5% concentration of MWCNT particles reduced this temperature by approximately 18%. On the other hand, higher concentrations resulted in increased interface temperatures and worsened surface roughness due to particle deposition. Specifically, the use of 0.5% MWCNT improved surface finish by around 25%. The study concluded that machining performance benefits from nano-fluids only when used at optimal concentrations, as excessive amounts of nano-particles degrades performance-a finding supported by SEM analyses of the cutting inserts.

Keywords

• Boron mineral oil–water mixture
• Nano-fluid
• Thermo-physical property
• Surface roughness
• Machining

Supporting Institution

Turkish Aerospace Incorporation

Thanks

The authors are grateful to Ankara Yıldırım Beyazıt University and Gazi University for their valuable support to this research. Besides, the authors express their gratitude to Turkish Aerospace Incorporation for their precious support.

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