A Comparative Evaluation of Dry-MQL Turning Applications for AISI 5115 Steel

Abstract

This study investigates the effect of various machining variables on cutting forces and surface roughness during turning of AISI 5115 steel in dry and MQL environments. While the experiments were carried out using two different feed rates, four different cutting speeds and constant depth of cut, the effects of them and their different levels on surface roughness and cutting forces were analyzed by reference to full factorial experimental design. The prominent findings of the research are as follows: The lowest surface roughness was obtained at 90 m/min cutting speed and 0.15 mm/rev feed rate in both mediums. The lowest cutting force was obtained at 135 m/min cutting speed, 0.15 mm/rev feed rate in dry environment and at 50 m/min cutting speed and 0.15 mm/rev feed rate in MQL environment. It was determined that there was an average 6.90% reduction in cutting force and an average 12.2% reduction in surface roughness in MQL condition. As a result, it was observed that machining in MQL conditions gave better results than dry conditions. These results show that the MQL method improves the machining performance compared to dry machining.

Keywords

• Turning
• MQL (minimum amount of lubrication)
• Dry Environment
• Surface Roughness
• Cutting Force

MQL Uygulaması ile AISI 5115 Çeliğinin Tornalama Performansının Değerlendirilmesi

Abstract

Bu çalışma, AISI 5115 çeliğinin kuru ve MQL ortamlarında tornalanması sırasında çeşitli işleme değişkenlerinin kesme kuvvetleri ve yüzey pürüzlülüğü üzerindeki etkisini araştırmaktadır. Deneyler iki farklı ilerleme, dört farklı kesme hızı ve sabit kesme derinliği kullanılarak gerçekleştirilirken parametrelerin ve farklı seviyelerinin yüzey pürüzlülüğü ve kesme kuvvetleri üzerindeki etkisi tam faktöriyel deney tasarımı referans alınarak analiz edilmiştir. Araştırmanın öne çıkan bulguları aşağıdaki gibidir: En düşük yüzey pürüzlülüğü her iki ortamda da 90 m/dak kesme hızı ve 0,15 mm/dev ilerleme hızında elde edilmiştir. En düşük kesme kuvveti, kuru ortamda 135 m/dak kesme hızı ve 0.15 mm/dev ilerleme hızında, MQL ortamında ise 50 m/dak kesme hızı ve 0.15 mm/dev ilerleme hızında elde edilmiştir. MQL koşulunda kesme kuvvetinde ortalama %6,90 ve yüzey pürüzlülüğünde ortalama %12,2 azalma olduğu tespit edilmiştir. Sonuç olarak, MQL koşullarında işlemenin kuru koşullara göre daha iyi sonuçlar verdiği gözlemlenmiştir. Bu sonuçlar, MQL yöntemininkuru işlemeye nazaran işleme performansını iyileştirdiğini göstermektedir.

Keywords

• Tornalama
• MQL (minimum miktarda yağlama)
• Kuru Ortam
• Yüzey Pürüzlülüğü
• Kesme Kuvveti

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