Evaluation of the Relationship of Surface Roughness with Machining Parameters in Milling of AA 7075 Material with Experimental and Deform 3D Simulation

Yıl 2023, Cilt: 19 Sayı: 2, 175 - 182, 29.06.2023

Ömer Erkan

Öz

AA 7075 T6 material offers important strength values and is easy to machining. In this respect, it is preferred on a wide scale in the industry. This study aimed to investigate the surface quality that occurs in the end milling of AA 7075 T6 material. For this, 3 different cutting speeds (40, 80, 120 m/min), three different feed rates (0.04, 0.08, 0.12 mm/rev), 2 different cutting depths (1 and 2 mm) were selected. The selected cutting parameters are combined with 2 and 4-flute end mills. As a result of the experiments, the average surface roughness (Ra) value was measured. The relations of Ra values with the cut parameters were determined. It was determined that Ra increased with increasing feed rate and decreased with increasing cutting speed. No significant effect of depth of cut was detected. Increasing the number of mouths increased Ra. The milling simulation was performed with the 3D cutting module in the Deform 3D software. 2 and 4 flute end mills are modeled, and the workpiece is defined to the software and the cutting parameters. Temperature, damage, stress, and cutting force outputs were estimated through simulations run at different cutting parameters. The predicted outputs and the experimental Ra outputs were interpreted and interpreted. Experimental outputs were supported by successfully applying milling simulation in Deform 3D software.

Anahtar Kelimeler

AA 7075 T6, milling, surface roughness, flute number, Deform 3D, simulation

Kaynakça

• Rendigs, K.H. 1997. “Aluminum structures used in aerospace Status and prospects”[J]. Mater Sci Forum.
• Williams, J.C.,Jr Starke E.A., 2003. “Progress in structural materials for aerospace systems [J]”, Acta Mater.
• Demirci, H., 2004. Malzeme Bilgisi ve Malzeme Muayenesi Seçilmiş Temel Kavramlar ve Endüstriyel Uygulamalar, Alfa Basım Yayın.
• Kakati,A.K.,Chandrasekaran,M.,Mandal,A.,SinghA.K.2011. “Prediction of optimum cutting parameters to obtain desired surface in finish pass end milling of aluminium alloy with carbide tool using artificial neural network”, World Academy Of Science And Engineering and Technology, Volume 5, Number 9, p.1929-1935.
• Salguero Gómez, J. Analysis, 2013. Evaluation and Proposals for Performance Enhancing in Highspeed Machining of Aeronautical Aluminum Alloys. Ph.D. Thesis, University of Cadiz, Cadiz, Spain.
• Baek,D.K.;Ko,T.J.;Kim,H.S.2001.Optimizationoffeedraterate in a face milling operation using a surface roughness model. Int. J. Mach. Tools Manuf., 41, 451–462
• Salguero,J.;Batista,M.;Calamaz,M.;Girot,F.;Marcos,M.2013. Cutting forces parametric model for the dry highspeed contour milling of aerospace aluminum alloys. Procedia Eng., 63, 735–742.
• Cai, X.J.; Ming,W.W.; Chen, M. 2012. Surface integrity analysis on high speed end milling of 7075 aluminium alloy. Adv. Mater. Res., 426, 321–324.
• Ammula, S.C.; Guo, Y.B. 2005. Surface integrity of Al 7050- T7451 and Al 6061-T651 induced by high speed milling. J. Aerosp.
• Yang, J. L.; Chen, J. C. 2001. A systematic approach for identifying optimum surface roughness performance in end-milling. // J Ind Technol. 17, 2, pp. 1-8.
• Brezocnik, M.; Kovacic, M; Ficko, M. 2004.Prediction of surface roughness with genetic programming. // J Mater Process Technol. 157- 158, pp. 28-36.
• Wang, M. Y.; Chang, H. Y. 2004. Experimental study of surface roughness in slot end milling Al2014-T6. // Int J Mach Tools Manuf. 44, (2004), pp. 51-57.
• Simunovic, G.; Simunovic, K.; Saric, T. 2013. Modelling and Simulation of Surface Roughness in Face Milling. // International Journal of Simulation Modelling. 12, 3, pp. 141-153.
• Saric, T.; Simunovic, G.; Simunovic K. 2013. Use of Neural Networks in Prediction and Simulation of Steel Surface Roughness. // International Journal of Simulation Modelling. 12, 4, pp. 225-236.
• Zaghbani, I., Songmene V. 2009. “A force-temperature model including a constitutive law for dry high speed milling of aluminium alloys”, Journal of Materials Processing Technology, Volume 209, Number 5,
• Hüseyinoğlu, M., 2008. 7075 Alüminyum Alaşımın Freze ile İşlenmesinde Minimum Soğutma Sıvısı Kullanmanın Performans Karakteristiklerine Etkisi. Fırat Ü. Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi, 48s, Elazığ
• Bayraktar, Ş., Turgut, Y, 2016. “Al-5083 Alaşımının Frezelenmesinde Kesme Kuvveti, Yüzey Pürüzlülüğü Ve Çapak Yüksekliğinin Optimizasyonu” 7th International Symposium On Machining, November 3-5, Marmara University, Istanbul
• Erkan Ö., Yücel E. 2018 “Parmak frezelenen AA 7075 malzemenin yüzey pürüzlülüğünün kesme parametreleri ve takım geometrisi ile olan ilişkisinin optimizasyou” International Eurasian Conference on Science, Engineering and Technology (EurasianSciEnTech 2018), November 22-23, 2018 Ankara, Turkey
• Vishwakarma P., Sharma A., 2020 “3D Finite Element Analysis of milling process for non-ferrous metal using deform-3D”, Materials Today: Proceedings, Volume 26, Part 2, Pages 525-528,
• Natarajan, M.M., Chinnasamy, B., Alphonse, B.H.B., 2022 “Deform 3D Simulation and Experimental Investigation of Fixtures with Support Heads” MECHANIKA Volume 28(2): 130−138
• Okokpujie, I.P.; Chima, P.C.; Tartibu, L.K. 2022, “Experimental and 3D-Deform Finite Element Analysis on ToolWear during Turning of Al-Si-Mg Alloy” Lubricants, 10, 341.