Optimization of Cutting Forces During Turning of Composite Materials

Abstract

Composites are the type of materials designed and produced according to their usage area. Therefore, composite materials can be produced in accordance with the usage area using the same production method. This situation affects the machinability properties of composites, owing to the fact that different production parameters cause different mechanical properties. For this reason, it is important that the determination and optimization of cutting forces during machining of composite materials. In this context, the optimization of cutting forces of bronze matrix (CuSn10) composites which are reinforced with cast iron (GGG-40) produced using 3 different production temperatures (350,400 and 450˚C) and pressure (480, 640 and 820 MPa) and 4 different reinforcement (wt. %10, wt. %20, wt. %30, wt. %40) during dry turning. Full factorial design based 36 experiments were performed and resultant force calculation was carried out with measurement of cutting forces in 3 axes. During experiments cutting conditions were kept constant (cutting speed=50 m/min, feed rate=0,128 mm/rev and depth of cut=1 mm). As a result of analysis of variance (ANOVA), it was found that the parameter which has the most effect on the cutting forces is the production pressure with 80% contribution rate.

Keywords

• Composite materials,turning,optimization,cutting forces,analysis of variance

Kompozit Malzemelerin Tornalanması Esnasında Oluşan Kesme Kuvvetlerinin Optimizasyonu

Abstract

Kompozit malzemeler kullanılacağı yere göre tasarlanan ve üretilen malzemelerdir. Dolayısıyla kompozit malzemeler aynı üretim metodu kullanılarak kullanılacağı yere göre farklı üretim parametrelerinde üretilebilir. Farklı üretim parametrelerinde üretilen kompozit malzemeler farklı mekanik özelliklere sahip olacağı için bu durum kompozit malzemelerin işlenebilirlik özelliklerini etkiler. Bu sebeple kompozit malzemelerin işlenmesi esnasında oluşan kesme kuvvetlerinin tespit edilmesi ve optimizasyonu önem arz etmektedir. Bu kapsamda, 3 farklı üretim sıcaklığı (350, 400 ve 450˚C) ve basıncı (480, 640 ve 820 MPa) ile 4 farklı karışım oranında (ağ. %10, ağ. %20, ağ. %30, ağ. %40) üretilen dökme demir (GGG-40) takviyeli ve bronz matrisli (CuSn10) kompozit malzemelerin kuru kesme şartlarında tornalanması esnasında kesme kuvvetlerinin optimizasyonu gerçekleştirilmiştir. Tam faktöriyel tasarım prensibi ile 36 deney yapılmış ve üç eksende kesme kuvvetleri ölçümü alınarak bileşke kesme kuvveti hesabı yapılmıştır. Deneyler esnasında kesme şartları sabit tutulmuştur (kesme hızı=50 m/dak, ilerleme=0,128 mm/dev ve talaş derinliği=1 mm). Varyans analizi (ANOVA) neticesinde bileşke kesme kuvveti üzerine en çok etkisi olan parametrenin %80 katkı oranıyla birlikte üretim basıncı olduğu tespit edilmiştir

Keywords

• Kompozit malzemeler,tornalama,optimizasyon,kesme kuvvetleri,varyans analizi

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