Prediction of the Production Quality During Flat Bottom Drilling of Low Lead Brass Alloy Using Fuzzy Logic and Regression Models

Abstract

İçme suyu ve pompa sistemlerinde kullanılan pirinç alaşımlarının kimyasal bileşiminde Kurşun elementinin bulunmasına ilişkin onaylanmış kısıtlayıcı kurallar, yeni malzeme nesillerinin geliştirilmesini sağlamıştır. Bu unsurun ihmal edilmesi veya sınırlandırılması, endüstriyi geleneksel olanlara göre daha düşük işlenebilirlik gibi ciddi sorunlarla karşı karşıya bırakmıştır. Ayrıca bu alaşımlardan imal edilen bileşenlerin en çok uygulaması sıvı transferine denk geldiği için parçalar ve yüzeyleri arasındaki geçirgenlik özelliği ön plana çıkmaktadır. Bu çalışmada, düşük kurşunlu pirinç alaşımının işlenmesi için radyal, eksenel eğim açısı ve kesici kenar yarıçapı gibi çeşitli geometrilere sahip düz tabanlı matkaplarla işlenmiş kör deliklerin kalitesi araştırılmıştır. Ayrıca, işlenmiş deliklerin çapak yüksekliğini ve yüzey kalitesini tahmin etmek için bulanık mantık ve regresyon modelleri geliştirilmeye çalışılmıştır. Model tahminleri deneysel verilerle karşılaştırılmıştır. Elde edilen sonuçlar, geliştirilen modellerin ürün kalitesini tahmin edebildiğini göstermiştir.

Keywords

• Flat bottom drill
• low-lead brass
• fuzzy logic
• regression.

Prediction of the Production Quality During Flat Bottom Drilling of Low Lead Brass Alloy using Fuzzy Logic and Regression models

Abstract

The approved restrictive rules on the containment of Lead element in the chemical composition of the brass alloys which are utilized in drinking water and pumping systems have resulted in developing of new material generations. Neglection or limitation of this element has faced the industry with some serious problems such as lower machinability as compared to the conventional ones. Furthermore, since the most application of the manufactured components from these alloys corresponds to the fluids transfer, the permeability property between the parts and their surface becomes prominent. In other words, any burrs or extra material which are left on the surfaces of manufactured components will make assembly troublesome, causing seals to tear, and permeability problems in the user's hands. In this study, the quality of the machined blind holes with flat bottom drills with various geometries including radial, axial rake angle as well as the cutting edge-radius have been investigated for machining of low-lead brass alloy. Moreover, it has attempted to develop fuzzy logic and regression models in order to predict the machined holes burr height and surface quality. The model predictions have been compared with the experimental data. The obtained results have demonstrated that the developed models are able in predicting of the product quality.

Keywords

• Flat bottom drill
• low-lead brass
• fuzzy logic
• regression.

References

1. [1] K. Aytekin, Characterization of machinability in lead-free brass alloys, PhD thesis, KTH Royal institute of technology, Sweden (2018).
2. [2] M. Adineha, H. Doostmohammadi, Microstructure, mechanical properties and machinability of Cu–Zn–Mg and Cu–Zn–Sb brass alloys, Journal of Materials Science and Technology, 35(12), 1504–1514, (2019).
3. [3] https://www.copper.org/applications/rodbar/pdf/A7038-brass-for-european-potable-water-applications.pdf
4. [4] https://rohs.exemptions.oeko.info/fileadmin/user_upload/RoHS_Pack_9/Exemption_6_c_/Exemption_6c__2015-10-mitsubishi-shindoh-rohs.pdf
5. [5] D. Peters, Bismuth Modified Cast Red Brasses to Meet U.S. Drinking Water Standards, Copper Development Association, (1995).
6. [6] D. Davies, Bismuth in copper and copper base alloys: a literature review, Technical Report, Copper Development Association, (1993).
7. [7] L. Amaral, R. Quinta, T.E. Silva, R.M. Soares, S.D. Castellanos, A.M.P. de Jesus, Effect of lead on the machinability of brass alloys using polycrystalline diamond cutting tools, Journal of Strain Analysis for Engineering Design, 53(8), 602–615, (2018).
8. [8] N. Gane, The effect of lead on the friction and machining of brass, Journal of Philosophical Magazine A, 43(3), (1981).

9. [9] E.M. Trent, P.K. Wright, Metal Cutting, 4th ed., Butterworth-Heinemann, Stoneham, MA, USA, (2000).
10. [10] E.M. Trent, Metal cutting and the tribology of seizure: III temperatures in metal cutting, Journal of Wear, 128, 65–81, (1988).
11. [11] V. Bushlya, D. Johansson, F. Lenrick, J. E. Ståhl, F. Schultheiss, Wear mechanisms of uncoated and coated cemented carbide tools in machining lead-free silicon brass, Journal of Wear, (376-377), 143-151, (2017).
12. [12] F. Schultheiss, D. Johansson, V. Bushlya, J. Zhou, K. Nilsson, J. E. Ståhl, Comparative study on the machinability of lead-free brass, Journal of Cleaner Production, 149, 366-377, (2017).
13. [13] C. Nobel, F. Klocke, D. Lung, S. Wolf, Machinability Enhancement of Lead-Free Brass Alloys, Journal of Procedia CIRP, 14, 95-100, (2014).
14. [14] A. I. Toulfatzis, G. A. Pantazopoulos, C. N. David, D. S. Sagris, A. S. Paipetis, Machinability of Eco-Friendly Lead-Free Brass Alloys: Cutting-Force and Surface-Roughness Optimization, Journal of Metals, 8, 250, (2018).
15. [15] N. Zoghipour, E. Tascioglu, G. Ataya, Y. Kaynak, Machining-induced surface integrity of holes drilled in lead-free brass alloy, Journal of Procedia CIRP, 87, 148-152, (2020).
16. [16] J. Hua, R. Shivpuri, X. Cheng, V. Bedekar, Y. Matsumoto, F. Hashimoto, T. R. Watkins. Effect of feed rate, workpiece hardness and cutting edge on subsurface residual stress in the hard turning of bearing steel using chamfer + hone cutting edge geometry, Journal of Materials Science and Engineering A, 394, 238–248, (2005).
17. [17] H. Kato, S. Nakata, N. Ikenaga, Improvement of chip evacuation in drilling of lead-free brass using micro drill, International Journal of Automation Technology, 8, (2014).
18. [18] M. Timata, C. Saikaew. Influences of spindle speed and feed rate on exit burr height and workpiece diameter in drilling forging brass, Solid state phenomena, 279, 67-71, (2018).
19. [19] N. Zoghipour, G. Atay, Y. Kaynak, Modeling and optimization of drilling operation of lead-free brass alloys considering various cutting tool geometries and copper content, Journal of Procedia CIRP, 102, 246-251, (2021).
20. [20] https://sarbak.com.tr/dokuman/alasimlar/en/S511.pdf
21. [21] F. Galton, Regression towards mediocrity in hereditary stature, The Journal of the Anthropological Institute of Great Britain and Ireland, 15, 246–263, (1886).
22. [22] I. J. Jeong, K. J. Kim, An interactive desirability function method to multiresponse optimization, European Journal of Operational Research, 195, 412–426, (2009).
23. [23] D. C. Montgomery, Design and Analysis of Experiments, John Wiley, New York, NY, USA, 2nd. (1984).