Optimization of Cutting Parameters for Surface Roughness in Milling of Cryogenic Treated EN AW 5754 (AlMg3) Aluminum Alloy

Year 2019, , 665 - 673, 01.09.2019

Gürcan Samtaş Salih Korucu

https://doi.org/10.2339/politeknik.457957

Cited By: 2

Abstract

Aluminum alloys are
now widely used in plastic injection molds in the automotive and aerospace
industries due to their high strength and weight ratio, good corrosion and
fatigue resistance. In this study, EN AW 5754
(AlMg₃) 5754
aluminum alloy with dimensions of 80x80x30 mm was subjected to cryogenic
treatment, face milling was performed with coated and uncoated inserts, and then
the effects of cutting parameters on surface roughness during face milling were
examined. The experiments were conducted with Taguchi L₉ orthogonal
array, using three different cutting inserts (Al₂O₃-TiCN-TiN
coated, TiAlN coated Nano, TiB₂ coated), cutting speeds (310, 450,
600 m / min), feed rates (0.15, 0.25, 0.35 mm / tooth) and depths of cut (0.5,
1, 1.5 mm). The values obtained at the end of the experiments were evaluated
using signal-to-noise ratio (S/N), variance analysis (ANOVA), three-dimensional
graphs and regression method. Taguchi analysis has revealed that optimum
cutting conditions for the minimum surface roughness are the Al₂O₃-TiCN-TiN
coated insert, 1 mm depth of cut, 600 m/min cutting speed and 0.15 mm/tooth
feed rate. The surface roughness values for these cutting conditions were found
as 0.47 μm in the calculations and 0.32 μm in the verification experiments.

Keywords

EN AW 5754, surface roughness, cryogenic process, Taguchi method

Kriyojenik İşlem Görmüş EN AW 5754 (AlMg3) Alüminyum Alaşımının Frezelenmesinde Yüzey Pürüzlülüğü İçin Kesme Parametrelerinin Optimizasyonu

Abstract

Alüminyum alaşımları günümüzde, yüksek dayanım
ve ağırlık oranı, iyi korozyon ve yorulma direnci nedeniyle, otomotiv ve
havacılık sanayinde, plastik enjeksiyon kalıplarında yaygın bir şekilde
kullanılmaktadır. Bu çalışmada, 80x80x30 mm ebatlarında EN AW 5754 (AlMg₃)  alüminyum alaşımına kriyojenik işlem
uygulanmış, kaplamalı ve kaplamasız kesici uçlarla yüzey frezeleme işlemi
gerçekleştirilmiş ve yüzey frezeleme işlemi esnasında kesme parametrelerinin
yüzey pürüzlülüğü üzerindeki etkileri araştırılmıştır. Deneylerde Taguchi L₉
ortogonal dizini ile üç farklı kesici uç (Al₂O₃-TiCN-TiN
kaplamalı, TiAlN kaplamalı Nano, TiB₂ kaplamalı), kesme hızı (310,
450, 600 m/dak), ilerleme oranı (0.15, 0.25, 0.35 mm/diş) ve üç farklı kesme
derinliği (0.5, 1, 1.5 mm) kullanılmıştır. Deneyler sonucunda elde edilen
değerler, sinyal-gürültü oranı (S/N), varyans analizi (ANOVA), üç boyutlu
grafikler ve regresyon metodu kullanılarak değerlendirilmiştir. Taguchi analizi
sonucu minimum yüzey pürüzlülüğü için elde edilen optimum kesme şartları; Al₂O₃-TiCN-TiN
kaplamalı kesici uç, 1 mm kesme derinliği, 600 m/dak kesme hızı ve 0.15 mm/diş ilerleme oranı olarak bulunmuştur. Bu
kesme şartları için yüzey pürüzlülük değerleri hesaplamalarda 0.47 µm olarak bulunmuş, doğrulama deneylerinde 0.32 µm olarak
ölçülmüştür.

Keywords

yüzey pürüzlülüğü, kriyojenik işlem, Taguchi metodu, EN AW 5754

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