Endüstriyel Tornalama İşlemlerinde Talaş Kırıcı Tasarımının Süreç Kalitesine Etkisinin Araştırılması

Abstract

Endüstriyel kuru tornalamada talaş kırıcı yiv tasarımının süreç kalitesini nasıl yönettiği; Ra, Fc,max ve talaş morfolojisi/kırılabilirliği ölçütleri üzerinden değerlendirilmiştir. AISI 1040–1060 çeliklerinde farklı yiv geometrilerine sahip uçlarla yürütülen karşılaştırmalı deneyler, Ra, Fc,max ve talaş akışı/kırılabilirliğinin yiv tasarımına duyarlılığını ortaya koymuştur. Literatürde son yıllarda, talaş kırıcı yiv genişliği ve arka duvar yüksekliği gibi ayrıntılı geometri parametrelerinin talaş kıvrılma yarıçapı ve kırılma üzerinde belirleyici olduğu, besleme hızının ise kırılabilirlikte baskın etkenlerden biri olduğu rapor edilmektedir. 3B/2B sonlu elemanlar (Johnson–Cook + Cockcroft–Latham) yaklaşımının ise talaş kırılma sürecini ve talaş akış açısını öngörmede güvenilir bir temel sunduğu gösterilmiştir. Bu çalışmada, deneysel gözlemler ile Taguchi tabanlı çok faktörlü değerlendirme birleştirilmiş; ayrıca talaş kırılabilirliği nitel/yarı-nicel göstergelerle desteklenmiştir. Bulgular, uygun talaş kırıcı geometrisinin seçilmesiyle talaş akış kararlılığının arttığını, enerji talebinin/ısı birikiminin azaldığını ve yüzey kalitesinin iyileştiğini göstermektedir. Sonuçlar, talaş kırıcı geometrisinin optimizasyonunun, modern tornalamada verimlilik ve kalite için kritik bir tasarım parametresi olduğunu doğrular. Bulgular, uygun kırıcı seçiminin talaş akışını kararlı kıldığını, kırılmayı kolaylaştırdığını ve Ra ile Fc,max dalgalanmasını azalttığını göstermiştir.

Keywords

• Talaş kırıcı geometrisi
• Talaş kırılabilirliği indeksi
• Talaş morfolojisi
• Yüzey pürüzlülüğü (Ra)
• Kesme kuvvetleri
• Kuru tornalama
• Taguchi S/N
• DEFORM tabanlı FEM

Investigation of the Influence of Chip Breaker Design on Process Quality in Industrial Turning Operations

Abstract

Under industrial dry‑turning conditions, this study quantifies how chip‑breaker design governs process quality—surface roughness (Ra), maximum cutting force (Fc,max), and chip morphology/breakability. Comparative experiments on AISI 1040 and AISI 1060 steels using inserts with different groove geometries reveal the sensitivity of Ra, Fc,max, and chip flow/breakability to groove design. Recent studies report that detailed groove parameters (e.g., groove width, back-wall height) govern chip curl radius and breakability, while feed is often the dominant factor; these insights inform our experimental plan. Finite element models employing the Johnson–Cook law and Cockcroft–Latham criterion reliably predict chip flow angle and chip breakage, providing an efficient design and screening tool for complex grooved inserts. Here, experimental observations are combined with Taguchi-based multi-factor analysis and semi-quantitative chip breakability metrics. The results show that selecting an appropriate chip breaker geometry stabilizes chip flow, reduces energy demand/thermal load, and improves surface finish, thus confirming chip breaker optimization as a critical lever for productivity and quality in modern turning. Results confirm that an appropriate breaker stabilizes chip flow, promotes breakage, and reduces variability in Ra and Fc,max.

Keywords

• Chip breaker geometry
• Chip breakability index
• Chip morphology
• Surface roughness (Ra)
• Cutting forces
• Dry turning
• Taguchi S/N
• DEFORM-based FEM

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