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

Year 2023, Volume: 13 Issue: 4, 2973 - 2985, 01.12.2023
https://doi.org/10.21597/jist.1310601

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.

References

  • Aized, T., & Amjad, M. (2013). Quality improvement of deep-hole drilling process of AISI D2. The International Journal of Advanced Manufacturing Technology, 69, 2493-2503.
  • Akıncıoğlu, S., Mendi, F., Çiçek, A., & Akıncıoğlu, G. (2013). Prediction of thrust forces and hole diameters using artificial neural networks in drilling of AISI D2 tool steel with cemented carbide tools. Academic Platform-Journal of Engineering and Science, 1(2), 11-20.
  • Akıncıoğlu, G., Mendi, F., Çiçek, A., & Akıncıoğlu, S. (2017). Taguchi optimization of machining parameters in drilling of AISI D2 steel using cryo-treated carbide drills. Sādhanā, 42, 213-222.
  • Akkuş, H., & Yaka, H. (2021). Optimization of cutting parameters in turning of titanium alloy (grade 5) by analysing surface roughness, tool wear and energy consumption. Experimental Techniques, 1-12.
  • Anthony, X. M. (2015). Analysis of cutting force and chip morphology during hard turning of AISI D2 steel. Journal of Engineering Science and Technology, 10(3), 282-290.
  • Bademlioglu, A. H., Canbolat, A. S., & Kaynakli, O. (2020). Multi-objective optimization of parameters affecting Organic Rankine Cycle performance characteristics with Taguchi-Grey Relational Analysis. Renewable and Sustainable Energy Reviews, 117.
  • Basavarajappa, S., Chandramohan, G., & Davim, J.P. (2008). Some studies on drilling of hybrid metal matrix composites based on Taguchi techniques. Journal of Materials Processing Technology, 196, 332–338.
  • Chou, C.W.C., Liu, X.D. (2000). Study on the various coated twist drills for stainless steels drilling. Journal of Materials Processing Technology, 99, 226-230.
  • Çakır, M.C. (2000). Modern talaşli imalat yöntemleri. Bursa: Vipaş.
  • Çırakoğlu, F., Özlü, B., Demir, H. (2021). Hardox 450 çeliğinin lazerle delinmesinde kesme parametrelerinin delik kalitesi üzerine etkisinin incelenmesi ve kesme parametrelerinin optimizasyonu. Bilecik Şeyh Edebali Üniversitesi Fen Bilimleri Dergisi, 8(2), 913-923.
  • Çiçek, A. Kıvak, T. & Samtaş, G. (2012). Application of Taguchi method for surface roughness and roundness error in drilling of AISI 316 stainless steel”. Strojniški Vestnik - Journal of Mechanical Engineering, 58(3), 165-174.
  • Duran, A.& Acır, A. (2004). HSS torna kalemindeki talaş açisinin kesme kuvvetlerine etkisi. Polytechnic Journal, 211-215.
  • Jena, S. P., Mahapatra, S., & Acharya, S. K. (2021). Optimization of performance and emission characteristics of a diesel engine fueled with Karanja biodiesel using Grey-Taguchi method. Materials Today: Proceedings, 41, 180-185.
  • Kumar, P., Singh, G., Jain, V., & Gupta, D. (2018). Optimization of process parameters for improving drilling quality and machining performance of abrasive assisted drilling on AISI D2 steel. Indian Journal of Engineering & Materials Sciences, 25, 33-41.
  • La Monaca, A., Murray, J. W., Liao, Z., Speidel, A., Robles-Linares, J. A., Axinte, D. A., ... & Clare, A. T. (2021). Surface integrity in metal machining-Part II: Functional performance. International Journal of Machine Tools and Manufacture, 164, 103718.
  • Li, G., Huang, Z., & Wang, X. (2017). The FEM simulation on end mill of plastic doors and windows corner cleaning based on deform-3D. In IOP Conference Series: Materials Science and Engineering, 272(1), 012009.
  • Luo, H., Fu, J., Wu, T., Chen, N., & Li, H. (2021). Numerical simulation and experimental study on the drilling process of 7075-t6 aerospace aluminum alloy. Materials, 14(3), 553.
  • Malo, Y., Yaka, H. (2023). Evaluating the parameters for electrode wear rate in electrical discharge machining of H13 steel. Selcuk University Journal of Engineering Sciences, 22(1), 33-37.
  • Mustapha, A. N., Zhang, Y., Zhang, Z., Ding, Y., Yuan, Q., & Li, Y. (2021). Taguchi and ANOVA analysis for the optimization of the microencapsulation of a volatile phase change material. Journal of Materials Research and Technology, 11, 667-680.
  • Nosouhi, M., Nosouhi, R., Paktinat, H., & Amini, S. (2017). Finite element analysis and experimental investigation on the conventional and vibration assisted drilling. Journal of Modern Processes in Manufacturing and Production, 6(4), 23-33.
  • Nguyen, T. C., Miska, S., Saasen, A., & Maxey, J. (2014). Using Taguchi and ANOVA methods to study the combined effects of drilling parameters on dynamic barite sag. Journal of Petroleum Science and Engineering, 121, 126-133.
  • Raju, B. P., & Swamy, M. K. (2012). Finite element simulation of a friction drilling process using deform-3D. International Journal of Engineering Research and Applications, 2(6), 716-721.
  • Shapiro, A. (2009). Finite element modeling of hot stamping. Steel Research International, 80, 658.
  • Sharif, S., & Rahim, E.A. (2007). Performance of coated and uncoated-carbide tools when drilling titanium alloy-Ti–6Al4V. Journal of Materials Processing Technology, 185, 72-76.
  • Osman, M. H., Hadzley, M., Tamin, N. F., Mohamad, N. J., Wahid, M. K., Ahmad, M. N., ... & Ab Rahman, M. H. (2017). Optimization of drilling parameters in diameter accuracy on dry drilling process of AISI D2 tool steel. Proceedings of Mechanical Engineering Research Day, 105-106.
  • Osman, M. H., Tamin, N. F., Ahmad, M. N., Rahman, M. A., Wahid, M. K., Maidin, N. A., ... & Azahar, A. A. (2018). Effect of cutting parameters on surface roughness in dry drilling of AISI D2 tool steel by using Taguchi method. Journal of Advanced Manufacturing Technology (JAMT), 12(1 (2)), 535-546.
  • Özlü, B. (2021). Investigation of the effect of cutting parameters on cutting force, surface roughness and chip shape in turning of Sleipner cold work tool steel. Journal of the Faculty of Engineering and Architecture of Gazi University, 36(3), 1241-1251.
  • Özlü, B., Çelik, U., Demir, H. (2023). Serbest Formlu İnce Cidarlı AA 5083-H111 Alaşımının Frezelenmesinde Kesme Parametrelerinin Yüzey Pürüzlülüğü Üzerine Etkilerini Deneysel ve İstatiksel Değerlendirilmesi. Afyon Kocatepe Üniversitesi Fen ve Mühendislik Bilimleri Dergisi, 23(2), 512-522.
  • Sur., G., Erkan, Ö. (2018). Cutting tool geometry in the drilling of CFRP composite plates and Taguchi optimisation of the cutting parameters affecting delamination. Sigma Journal of Engineering and Natural Sciences, 36(3), 619-628.
  • Uğur, L., Kazan, H., Özlü, B. (2022). Investigation of the Impacts of Cutting Parameters on Power Usage in Cryogenic-Assisted Turning of AISI 52100 Bearing Steel by FEM. İmalat Teknolojileri ve Uygulamaları, 3(3), 55-61.
  • Ulaş, H. B. (2018). AISI D2 ve AISI D3 soğuk iş takım çeliklerinin delinmesinde kesme parametrelerinin kesme kuvvetleri üzerindeki etkisinin incelenmesi. Polytechnic Journal, 21(1), 251-256.
  • Yaka, H. (2021). Measurement of Surface Quality and Optimization of Cutting Parameters in Slot Milling of Gfrp Composite Materials with Different Fiber Ratios Produced by Pultrusion Method. Surface Review and Letters, 28(10), 2150095.

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

Year 2023, Volume: 13 Issue: 4, 2973 - 2985, 01.12.2023
https://doi.org/10.21597/jist.1310601

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%.

References

  • Aized, T., & Amjad, M. (2013). Quality improvement of deep-hole drilling process of AISI D2. The International Journal of Advanced Manufacturing Technology, 69, 2493-2503.
  • Akıncıoğlu, S., Mendi, F., Çiçek, A., & Akıncıoğlu, G. (2013). Prediction of thrust forces and hole diameters using artificial neural networks in drilling of AISI D2 tool steel with cemented carbide tools. Academic Platform-Journal of Engineering and Science, 1(2), 11-20.
  • Akıncıoğlu, G., Mendi, F., Çiçek, A., & Akıncıoğlu, S. (2017). Taguchi optimization of machining parameters in drilling of AISI D2 steel using cryo-treated carbide drills. Sādhanā, 42, 213-222.
  • Akkuş, H., & Yaka, H. (2021). Optimization of cutting parameters in turning of titanium alloy (grade 5) by analysing surface roughness, tool wear and energy consumption. Experimental Techniques, 1-12.
  • Anthony, X. M. (2015). Analysis of cutting force and chip morphology during hard turning of AISI D2 steel. Journal of Engineering Science and Technology, 10(3), 282-290.
  • Bademlioglu, A. H., Canbolat, A. S., & Kaynakli, O. (2020). Multi-objective optimization of parameters affecting Organic Rankine Cycle performance characteristics with Taguchi-Grey Relational Analysis. Renewable and Sustainable Energy Reviews, 117.
  • Basavarajappa, S., Chandramohan, G., & Davim, J.P. (2008). Some studies on drilling of hybrid metal matrix composites based on Taguchi techniques. Journal of Materials Processing Technology, 196, 332–338.
  • Chou, C.W.C., Liu, X.D. (2000). Study on the various coated twist drills for stainless steels drilling. Journal of Materials Processing Technology, 99, 226-230.
  • Çakır, M.C. (2000). Modern talaşli imalat yöntemleri. Bursa: Vipaş.
  • Çırakoğlu, F., Özlü, B., Demir, H. (2021). Hardox 450 çeliğinin lazerle delinmesinde kesme parametrelerinin delik kalitesi üzerine etkisinin incelenmesi ve kesme parametrelerinin optimizasyonu. Bilecik Şeyh Edebali Üniversitesi Fen Bilimleri Dergisi, 8(2), 913-923.
  • Çiçek, A. Kıvak, T. & Samtaş, G. (2012). Application of Taguchi method for surface roughness and roundness error in drilling of AISI 316 stainless steel”. Strojniški Vestnik - Journal of Mechanical Engineering, 58(3), 165-174.
  • Duran, A.& Acır, A. (2004). HSS torna kalemindeki talaş açisinin kesme kuvvetlerine etkisi. Polytechnic Journal, 211-215.
  • Jena, S. P., Mahapatra, S., & Acharya, S. K. (2021). Optimization of performance and emission characteristics of a diesel engine fueled with Karanja biodiesel using Grey-Taguchi method. Materials Today: Proceedings, 41, 180-185.
  • Kumar, P., Singh, G., Jain, V., & Gupta, D. (2018). Optimization of process parameters for improving drilling quality and machining performance of abrasive assisted drilling on AISI D2 steel. Indian Journal of Engineering & Materials Sciences, 25, 33-41.
  • La Monaca, A., Murray, J. W., Liao, Z., Speidel, A., Robles-Linares, J. A., Axinte, D. A., ... & Clare, A. T. (2021). Surface integrity in metal machining-Part II: Functional performance. International Journal of Machine Tools and Manufacture, 164, 103718.
  • Li, G., Huang, Z., & Wang, X. (2017). The FEM simulation on end mill of plastic doors and windows corner cleaning based on deform-3D. In IOP Conference Series: Materials Science and Engineering, 272(1), 012009.
  • Luo, H., Fu, J., Wu, T., Chen, N., & Li, H. (2021). Numerical simulation and experimental study on the drilling process of 7075-t6 aerospace aluminum alloy. Materials, 14(3), 553.
  • Malo, Y., Yaka, H. (2023). Evaluating the parameters for electrode wear rate in electrical discharge machining of H13 steel. Selcuk University Journal of Engineering Sciences, 22(1), 33-37.
  • Mustapha, A. N., Zhang, Y., Zhang, Z., Ding, Y., Yuan, Q., & Li, Y. (2021). Taguchi and ANOVA analysis for the optimization of the microencapsulation of a volatile phase change material. Journal of Materials Research and Technology, 11, 667-680.
  • Nosouhi, M., Nosouhi, R., Paktinat, H., & Amini, S. (2017). Finite element analysis and experimental investigation on the conventional and vibration assisted drilling. Journal of Modern Processes in Manufacturing and Production, 6(4), 23-33.
  • Nguyen, T. C., Miska, S., Saasen, A., & Maxey, J. (2014). Using Taguchi and ANOVA methods to study the combined effects of drilling parameters on dynamic barite sag. Journal of Petroleum Science and Engineering, 121, 126-133.
  • Raju, B. P., & Swamy, M. K. (2012). Finite element simulation of a friction drilling process using deform-3D. International Journal of Engineering Research and Applications, 2(6), 716-721.
  • Shapiro, A. (2009). Finite element modeling of hot stamping. Steel Research International, 80, 658.
  • Sharif, S., & Rahim, E.A. (2007). Performance of coated and uncoated-carbide tools when drilling titanium alloy-Ti–6Al4V. Journal of Materials Processing Technology, 185, 72-76.
  • Osman, M. H., Hadzley, M., Tamin, N. F., Mohamad, N. J., Wahid, M. K., Ahmad, M. N., ... & Ab Rahman, M. H. (2017). Optimization of drilling parameters in diameter accuracy on dry drilling process of AISI D2 tool steel. Proceedings of Mechanical Engineering Research Day, 105-106.
  • Osman, M. H., Tamin, N. F., Ahmad, M. N., Rahman, M. A., Wahid, M. K., Maidin, N. A., ... & Azahar, A. A. (2018). Effect of cutting parameters on surface roughness in dry drilling of AISI D2 tool steel by using Taguchi method. Journal of Advanced Manufacturing Technology (JAMT), 12(1 (2)), 535-546.
  • Özlü, B. (2021). Investigation of the effect of cutting parameters on cutting force, surface roughness and chip shape in turning of Sleipner cold work tool steel. Journal of the Faculty of Engineering and Architecture of Gazi University, 36(3), 1241-1251.
  • Özlü, B., Çelik, U., Demir, H. (2023). Serbest Formlu İnce Cidarlı AA 5083-H111 Alaşımının Frezelenmesinde Kesme Parametrelerinin Yüzey Pürüzlülüğü Üzerine Etkilerini Deneysel ve İstatiksel Değerlendirilmesi. Afyon Kocatepe Üniversitesi Fen ve Mühendislik Bilimleri Dergisi, 23(2), 512-522.
  • Sur., G., Erkan, Ö. (2018). Cutting tool geometry in the drilling of CFRP composite plates and Taguchi optimisation of the cutting parameters affecting delamination. Sigma Journal of Engineering and Natural Sciences, 36(3), 619-628.
  • Uğur, L., Kazan, H., Özlü, B. (2022). Investigation of the Impacts of Cutting Parameters on Power Usage in Cryogenic-Assisted Turning of AISI 52100 Bearing Steel by FEM. İmalat Teknolojileri ve Uygulamaları, 3(3), 55-61.
  • Ulaş, H. B. (2018). AISI D2 ve AISI D3 soğuk iş takım çeliklerinin delinmesinde kesme parametrelerinin kesme kuvvetleri üzerindeki etkisinin incelenmesi. Polytechnic Journal, 21(1), 251-256.
  • Yaka, H. (2021). Measurement of Surface Quality and Optimization of Cutting Parameters in Slot Milling of Gfrp Composite Materials with Different Fiber Ratios Produced by Pultrusion Method. Surface Review and Letters, 28(10), 2150095.
There are 32 citations in total.

Details

Primary Language English
Subjects Materials Engineering (Other)
Journal Section Metallurgical and Materials
Authors

Harun Yaka 0000-0003-4859-9609

Kaan Engin 0000-0002-6439-7700

Early Pub Date November 30, 2023
Publication Date December 1, 2023
Submission Date June 6, 2023
Acceptance Date July 12, 2023
Published in Issue Year 2023 Volume: 13 Issue: 4

Cite

APA Yaka, H., & Engin, K. (2023). Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel. Journal of the Institute of Science and Technology, 13(4), 2973-2985. https://doi.org/10.21597/jist.1310601
AMA Yaka H, Engin K. Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel. J. Inst. Sci. and Tech. December 2023;13(4):2973-2985. doi:10.21597/jist.1310601
Chicago Yaka, Harun, and Kaan Engin. “Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel”. Journal of the Institute of Science and Technology 13, no. 4 (December 2023): 2973-85. https://doi.org/10.21597/jist.1310601.
EndNote Yaka H, Engin K (December 1, 2023) Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel. Journal of the Institute of Science and Technology 13 4 2973–2985.
IEEE H. Yaka and K. Engin, “Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel”, J. Inst. Sci. and Tech., vol. 13, no. 4, pp. 2973–2985, 2023, doi: 10.21597/jist.1310601.
ISNAD Yaka, Harun - Engin, Kaan. “Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel”. Journal of the Institute of Science and Technology 13/4 (December 2023), 2973-2985. https://doi.org/10.21597/jist.1310601.
JAMA Yaka H, Engin K. Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel. J. Inst. Sci. and Tech. 2023;13:2973–2985.
MLA Yaka, Harun and Kaan Engin. “Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel”. Journal of the Institute of Science and Technology, vol. 13, no. 4, 2023, pp. 2973-85, doi:10.21597/jist.1310601.
Vancouver Yaka H, Engin K. Improvement of Hole Qualities and Optimization of Machining Parameters Through Experimental and Finite Element Analysis in Drilling Of AISI D2 Cold Work Steel. J. Inst. Sci. and Tech. 2023;13(4):2973-85.