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

Year 2024, , 168 - 182, 26.06.2024

Havva Demirpolat

https://doi.org/10.55546/jmm.1488880

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

Abstract

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.

Keywords

5115 çelik, Tornalama, Kuru kesme, MMY, ANOVA

References

• Agarwal, S., Suman, R., Bahl, S., Haleem, A., Javaid, M., Sharma, M. K., . . . Singhal, P. , Optimisation of cutting parameters during turning of 16MnCr5 steel using Taguchi technique. International Journal on Interactive Design and Manufacturing (IJIDeM), 1-12, 2022.
• Amini, S., Khakbaz, H., & Barani, A., Improvement of near-dry machining and its effect on tool wear in turning of AISI 4142. Materials and Manufacturing Processes, 30(2), 241-247, 2015.
• Asiltürk, İ., Kuntoğlu, M., Binali, R., Akkuş, H., & Salur, E., A comprehensive analysis of surface roughness, vibration, and acoustic emissions based on machine learning during hard turning of AISI 4140 steel. Metals, 13(2), 437, 2023.
• Aslan, A., Salur, E., & Kuntoğlu, M., Evaluation of the role of dry and MQL regimes on machining and sustainability index of Strenx 900 steel. Lubricants, 10(11), 301, 2022.
• Ben Said, L., Kolsi, L., Ghachem, K., Almeshaal, M., & Maatki, C., Application of nanofluids as cutting fluids in machining operations: A brief review. Applied Nanoscience, 13(6), 4247-4278, 2023.
• Benardos, P., & Vosniakos, G.C., Predicting surface roughness in machining: a review. International journal of machine tools and manufacture, 43(8), 833-844, 2003.
• Binali, R., Coşkun, M., & Neşeli, S., An investigation of power consumption in milling AISI P20 plastic mold steel by finite elements method. Avrupa Bilim ve Teknoloji Dergisi(34), 513-518, 2022.
• Binali, R., Demirpolat, H., Kuntoğlu, M., & Sağlam, H., Machinability investigations based on tool wear, surface roughness, cutting temperature, chip morphology and material removal rate during dry and MQL-assisted milling of Nimax mold steel. Lubricants, 11(3), 101, 2023.
• Binali, R., Demirpolat, H., Kuntoğlu, M., & Salur, E., Different Aspects of Machinability in Turning of AISI 304 Stainless Steel: A Sustainable Approach with MQL Technology. Metals, 13(6), 1088, 2023.
• Binali, R., Patange, A. D., Kuntoğlu, M., Mikolajczyk, T., & Salur, E., Energy saving by parametric optimization and advanced lubri-cooling techniques in the machining of composites and superalloys: A systematic review. Energies, 15(21), 8313, 2022.
• Ghosh, S., & Rao, P. V., Application of sustainable techniques in metal cutting for enhanced machinability: a review. Journal of Cleaner Production, 100, 17-34, 2015.
• Grzesik, W., Denkena, B., Żak, K., Grove, T., & Bergmann, B., Energy consumption characterization in precision hard machining using CBN cutting tools. The International Journal of Advanced Manufacturing Technology, 85, 2839-2845, 2016.
• Gupta, M. K., Niesłony, P., Sarikaya, M., Korkmaz, M. E., Kuntoğlu, M., & Królczyk, G., Studies on geometrical features of tool wear and other important machining characteristics in sustainable turning of aluminium alloys. International Journal of Precision Engineering and Manufacturing-Green Technology, 10(4), 943-957, 2023.
• Harichand, S. C., & Sharma, S., Optimization of heat treatment process for 16MnCr5. International Journal of Engineering Science and Technology (IJEST), 4(3), 998-1004, 2012.
• Korkmaz, M. E., & Günay, M., Experimental and statistical analysis on machinability of Nimonic80A superalloy with PVD coated carbide. Sigma Journal of Engineering and Natural Sciences, 36(4), 1141-1152, 2018.
• Kuntoglu, M., Machining induced tribological investigations in sustainable milling of Hardox 500 steel: A new approach of measurement science. Measurement, 201, 111715, 2022.
• Lampman, S., Introduction to surface hardening of steels. ASM International, ASM Handbook., 4, 259-267, 1991.
• Mahapatra, S., Das, A., Jena, P. C., & Das, S. R., Turning of hardened AISI H13 steel with recently developed S3P-AlTiSiN coated carbide tool using MWCNT mixed nanofluid under minimum quantity lubrication. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 237(4), 843-864, 2023.
• Makhesana, M. A., & Patel, K. M., Performance assessment of vegetable oil-based nanofluid in Minimum Quantity Lubrication (MQL) during machining of Inconel 718. Advances in Materials and Processing Technologies, 8(3), 3182-3198, 2022.
• Mia, M., Mathematical modeling and optimization of MQL assisted end milling characteristics based on RSM and Taguchi method. Measurement, 121, 249-260, 2018.
• Mia, M., Gupta, M. K., Singh, G., Królczyk, G., & Pimenov, D. Y., An approach to cleaner production for machining hardened steel using different cooling-lubrication conditions. Journal of Cleaner Production, 187, 1069-1081, 2018.
• Mikolajczyk, T., Paczkowski, T., Kuntoglu, M., Patange, A. D., & Binali, R., Research on using an unconventional tool for increasing tool life by selective exchange of worn cutting edge. Applied Sciences, 13(1), 460, 2022.
• Mondal, K., Das, S., Mandal, B., & Sarkar, D., An investigation on turning hardened steel using different tool inserts. Materials and Manufacturing Processes, 31(13), 1770-1781, 2016.
• Monkova, K., Monka, P. P., Sekerakova, A., Hruzik, L., Burecek, A., & Urban, M., Comparative study of chip formation in orthogonal and oblique slow-rate machining of EN 16MnCr5 steel. Metals, 9(6), 698, 2019.
• Mutlu, B., Binali, R., Demirsöz, R., & Yaşar, N. , Machinability of CoCrMo Alloy used in Biomedical applications: Investigation of Cutting Tool Type. Gazi Mühendislik Bilimleri Dergisi, 8(2), 215-227, 2022.
• Pimenov, D. Y., da Silva, L. R. R., Machado, A. R., França, P. H. P., Pintaude, G., Unune, D. R., . . . Krolczyk, G. M., A Comprehensive Review of Machinability of Difficult-to-Machine Alloys with Advanced Lubricating and Cooling Techniques. Tribology International, 109677, 2024.
• Ross, N. S., Ganesh, M., Srinivasan, D., Gupta, M. K., Korkmaz, M. E., & Krolczyk, J., Role of sustainable cooling/lubrication conditions in improving the tribological and machining characteristics of Monel-400 alloy. Tribology International, 176, 107880, 2022.
• Salur, E., Kuntoğlu, M., Aslan, A., & Pimenov, D. Y., The effects of MQL and dry environments on tool wear, cutting temperature, and power consumption during end milling of AISI 1040 steel. Metals, 11(11), 1674, 2021.
• Sampaio, M. A., Machado, Á. R., Laurindo, C. A. H., Torres, R. D., & Amorim, F. L., Influence of minimum quantity of lubrication (MQL) when turning hardened SAE 1045 steel: a comparison with dry machining. The International Journal of Advanced Manufacturing Technology, 98, 959-968, 2018.
• Selçuk, B., Ipek, R., & Karamış, M., A study on friction and wear behaviour of carburized, carbonitrided and borided AISI 1020 and 5115 steels. Journal of Materials Processing Technology, 141(2), 189-196, 2003.
• Selçuk, B., Ipek, R., Karamiş, M., & Kuzucu, V., An investigation on surface properties of treated low carbon and alloyed steels (boriding and carburizing). Journal of Materials Processing Technology, 103(2), 310-317, 2000.
• Sen, B., Mia, M., Krolczyk, G. M., Mandal, U. K., & Mondal, S. P., Eco-friendly cutting fluids in minimum quantity lubrication assisted machining: a review on the perception of sustainable manufacturing. International Journal of Precision Engineering and Manufacturing-Green Technology, 8, 249-280, 2021.
• Şap, E., Usca, Ü. A., Şap, S., Polat, H., Giasin, K., & Kalyoncu, M., Understanding the effects of machinability properties of Incoloy 800 superalloy under different processing conditions using artificial intelligence methods. Materials Today Communications, 108521, 2024.
• Şap, S., Usca, Ü. A., Tarih, Y. S., Yar, A., Kuntoğlu, M., & Gupta, M. K., Novel use of cellulose based biodegradable nano crystals in the machining of PPS composites: An approach towards green machining. International Journal of Precision Engineering and Manufacturing-Green Technology, 11(1), 1-19, 2024. Usca, Ü. A., The Effect of Cellulose Nanocrystal-Based Nanofluid on Milling Performance: An Investigation of Dillimax 690T. Polymers, 15(23), 4521, 2023.
• Usca, Ü. A., Şap, S., Uzun, M., & Değirmenci, Ü., Assessment of the machinability and energy consumption characteristics of Cu–6Gr hybrid composites under sustainable operating. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 46(4), 221, 2024.
• Yallese, M. A., Chaoui, K., Zeghib, N., Boulanouar, L., & Rigal, J.F., Hard machining of hardened bearing steel using cubic boron nitride tool. Journal of Materials Processing Technology, 209(2), 1092-1104, 2009.
• Yurtkuran, H., Korkmaz, M. E., & Günay, M., Modelling and optimization of the surface roughness in high speed hard turning with coated and uncoated CBN insert. Gazi University Journal of Science, 29(4), 987-995, 2016.