Evaluation of the turning parameters of AISI 5115 steel in dry and MQL cutting environments with the use of a coated carbide cutting insert: An Experimental Study

Abstract

This study investigates the effects of cutting parameters on turning AISI 5115 steel in both dry and MQL environments using a coated carbide insert. The cutting parameters are determined using a full factorial design. A comprehensive full factorial experimental design was executed in order to investigate the effect of cutting parameters, including cutting speed, feed rate, and depth of cut, on surface roughness, cutting force and cutting temperature. Following the completion of the turning trials, surface roughness measurements were meticulously recorded. Also cutting force and cutting temperature were measured. The results of the study indicated that the most significant influence on surface roughness is exerted by the feed rate. Moreover, the impact of the depth of cut became more significant as the cutting speed decreased. While the surface roughness increased by 23% in the dry environment due to the increased feed rate at low cutting speed, the increase in the MQL environment was 32%. The cutting temperature is influenced by a number of factors, including the cutting parameters and the material properties. The maximum temperature for turning in the MQL environment was 381°C compared with an average cutting temperature of 430°C in dry machining conditions. The application of high-speed cutting in a dry cutting environment was found to result in a 10% increase in cutting temperature. The influence of cutting speed on the outcome was less pronounced in the MQL environment. At high cutting speeds and low parameter values in the MQL environment, the cutting force decreased by 75% in contrast to the low cutting speeds and high cutting parameters in the dry environment. The optimal cutting conditions for minimising cutting force were identified in the MQL environment, characterised by high cutting speeds and low feed rates.

Keywords

• 5115 steel
• Turning
• Dry Cutting
• MQL
• ANOVA

AISI 5115 çeliğinin kuru ve MQL kesme ortamında tornalama parametrelerinin kaplamalı karbür kesici uç kullanılarak değerlendirilmesi: Deneysel Bir Çalışma

Öz

Bu çalışma, kaplamalı karbür kesici uç kullanılarak AISI 5115 çeliğinin hem kuru hem de MQL ortamlarda tornalanmasında kesme parametrelerinin etkilerini araştırmaktadır. Kesme parametreleri tam faktöriyel tasarım kullanılarak belirlenmiştir. Kesme hızı, ilerleme hızı ve kesme derinliğini içeren kesme parametrelerinin yüzey pürüzlülüğü, kesme kuvveti ve kesme sıcaklığı üzerindeki etkisini araştırmak amacıyla kapsamlı bir tam faktöriyel deney tasarımı yürütülmüştür. Tornalama denemelerinin tamamlanmasının ardından yüzey pürüzlülük ölçümleri titizlikle kayıt altına alındı. Ayrıca kesme kuvveti ve kesme sıcaklığı da ölçülmüştür. Çalışmanın sonuçları, yüzey pürüzlülüğü üzerindeki en önemli etkinin ilerleme hızı tarafından uygulandığını göstermiştir. Ayrıca kesme hızının azalmasıyla kesme derinliğinin etkisi daha belirgin hale geldi. Kesme sıcaklığı, kesme parametreleri ve malzeme özellikleri de dahil olmak üzere bir dizi faktörden etkilenir. Kuru kesme ortamında yüksek hızlı kesme uygulamasının kesme sıcaklığında %10'luk bir artışa neden olduğu bulunmuştur. Kesme hızının sonuç üzerindeki etkisi MQL ortamında daha az belirgindi. Kesme kuvvetini en aza indirmek için en uygun kesme koşulları, yüksek kesme hızları ve düşük ilerleme hızları ile karakterize edilen MQL ortamında tanımlandı.

Anahtar Kelimeler

• 5115 çelik
• Tornalama
• Kuru kesme
• MMY
• ANOVA

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