A Numerical Study on Heat-Assisted Machining of Monel K-500 Alloy

Abstract

This study presents the investigation of the cutting force and chip formation process in hot machining of Monel K-500 alloy via finite element analysis. ThirdWave AdvantEdge software has been utilized for finite element analysis. For numerical analysis, cutting speed of 300 m/min, feed rate of 0.1 mm/rev, and 1 mm depth of cut have been selected as cutting parameters. Cutting simulations have been performed at room temperature (24°C) and four different heating temperatures (150°C, 300°C, 450°C, and 600°C) to determine the effect of hot processing. According to the results of the numerical analysis, it was observed that the cutting forces decreased in hot machining conditions compared to room temperature conditions, and the chip formed in the form of segmented chips in room temperature conditions, while it was formed as continuous type chips in hot machining conditions. The lowest cutting force value was measured as 315 N in numerical analyzes performed at 300 m/min cutting speed, 0.1 mm/rev feed rate, 1 mm depth of cut, and 600°C hot machining conditions. Moreover, it was determined that the cutting force decreased by approximately 34.14% at this heating temperature compared to the dry cutting condition.

Keywords

• Monel K-500
• Heat-Assisted Machining
• Cutting force
• Finite element analysis

Monel K-500 Alaşımının Isı Destekli İşlenmesi Üzerine Sayısal Bir Çalışma

Abstract

Bu çalışma, sonlu elemanlar analizi aracılığı ile Monel K-500 alaşımının sıcak işlenmesinde kesme kuvveti ve talaş oluşum sürecinin incelenmesini sunmaktadır. Sonlu elemanlar analizi için ThirdWave AdvantEdge yazılımı kullanılmıştır. Sayısal analizler için 300 m/dak kesme hızı (Vc), 0,1 mm/dev ilerleme miktarı (f) ve 1 mm talaş derinliği (a) kesme parametreleri olarak seçilmiştir. Sıcak işlemenin etkisini belirleyebilmek için simülasyonlar oda sıcaklığı (24°C) ve dört farklı ısıtma sıcaklığında (150°C, 300°C, 450°C ve 600°C) gerçekleştirilmiştir. Nümerik analiz sonuçlarına göre oda sıcaklığı koşullarına kıyasla sıcak işleme koşullarında kesme kuvvetlerinin azaldığı ve oda sıcaklığı koşullarında talaş dilimli talaş şeklinde oluşur iken sıcak işleme koşullarında ise sürekli talaş şeklinde oluştuğu görülmüştür. En düşük kesme kuvveti değeri 600°C sıcak işleme şartında gerçekleştirilen sayısal analizlerde 315 N olarak ölçülmüştür. Dahası, kuru kesme şartına göre bu ısıtma sıcaklığında kesme kuvvetinin yaklaşık %34,14 azaldığı tespit edilmiştir.

Keywords

• Monel K-500
• Isı destekli işleme
• Kesme kuvveti
• Sonlu elemanlar analizi

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