Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel

Abstract

Increasing supply chain problems in recent years have a negative impact on costs in many areas. Due to the global crisis, raw material prices increased and the manufacturing sector was seriously affected. Production planning and material saving should be done correctly in order to minimize the losses in the manufacturing sector. The most efficient way to reduce production costs is to use suitable cutting tools and choose the right machining parameters. In this study, the drilling of AISI D2 steel, which is widely used in the mold industry, was examined and optimum machining parameters were determined. TiN coated drills are used for drilling operations. The effects of machining parameters on Surface Roughness (Ra) and Thrust Force (Fz) were investigated by Taguchi and ANOVA. Surface roughness and thrust force values during drilling were measured. Thrust force values were also analyzed numerically by the Finite Element (FE) method. Ra and Fz were also low at low feed rate and low cutting speeds. While the feed rate affected Ra the most, the Fz affected the cutting speed the most. The lowest Ra and Fz were at 30 mm/min feed rate and 25 m/min cutting speed. According to the ANOVA, it was determined that the machining parameters were effective on both Ra and Fz. R2 values for Ra and Fz are calculated over 95%.

Keywords

• AISI D2
• ANOVA
• Drilling
• Finite Element
• Surface roughness
• Taguchi

AISI D2 Soğuk İş Çeliğinin Delinmesinde Deneysel ve Sonlu Elemanlar Analizi Yoluyla Delik Kalitelerinin İyileştirilmesi ve İşleme Parametrelerinin Optimizasyonu

Abstract

Son yıllarda artan tedarik sorunları birçok alanda maliyetlere olumsuz yansımaktadır. Global çapta meydana gelen krizlerden dolayı ham madde fiyatları artmış ve imalat sektörü de ciddi etkilenmiştir. İmalat sektöründe zararları minimize etmek için üretim planlaması ve malzeme tasarrufu doğru yapılmalıdır. Üretim giderlerini düşürmenin en verimli yolu da uygun kesici takım kullanmak ve doğru işleme parametrelerini seçmektir. Bu çalışmada kalıp sektöründe yaygın olarak kullanılan AISI D2 çeliğinin delinmesi incelenmiş ve optimum işleme parametreleri belirlenmiştir. Delme işlemleri için TiN kaplamalı matkaplar kullanılmıştır. İşleme parametrelerinin yüzey pürüzlülüğü (Ra) ve itme kuvveti (Fz) üzerindeki etkileri Taguchi ve ANOVA ile incelenmiştir. Delme işleminde oluşan yüzey pürüzlülüğü ve itme kuvveti değerleri ölçülmüştür. Ayrıca itme kuvveti değerleri sonlu elemanlar (FE) yöntemi ile de sayısal olarak incelenmiştir. Düşük ilerleme ve kesme hızlarında Ra ve Fz düşük çıkmıştır. Ra’ ya en çok ilerleme oranı etki ederken Fz’ye en çok kesme hızı etki etmiştir. En düşük Ra ve Fz, 30 mm/dak. ilerleme oranı ve 25 m/dak. kesme hızında olmuştur. ANOVA analizine göre, belirlenen işleme parametrelerinin hem Ra hem de Fz üzerinde etkili olduğu tespit edilmiştir. Ra ve Fz için R2 değerleri %95’in üzerinde hesaplanmıştır.

Keywords

• AISI D2
• ANOVA
• Delme
• Sonlu eleman
• Yüzey pürüzlülüğü
• Taguchi

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