A Research on The Evaluation of Performances After Re-Sharpening of The End Mills

Öz

In this study, the performances of end mills used widely in machining were investigated in case of their reuse by sharpening. For this purpose, at the CNC vertical machining center, slot milling processes were carried out with HSS end mills (used once) on the AISI 1050 manufacturing steel having two different diameters and with carbide end mills (again used once) on the AISI D2 (2080) cold work tool steel having two different diameters. Machining experiments were made by using four different cutting speeds, four different feed and four different cutting depths. These end mills, afterwards, were re-sharpened by considering their original tool geometry and the machining experiments were repeated at the same conditions and their performances were evaluated in comparison with the performances of the new tool. In general, wear amounts in the sharpened tools were observed to be higher with respect to the new tools. In the HSS tools, no adverse effect of sharpening process was observed on the machining performance. In the carbide tools, especially from the point of surface quality for the tools having small diameter there is no adverse effect of re-sharpening and re-sharpening can be recommended with the condition of observing the surface quality in parallel to the increase in diameter.

Anahtar Kelimeler

• Cutting Force
• Machining Performance
• Re-Sharpening
• Surface Roughness
• Tool Flank Wear

Parmak Frezelerin Yeniden Bileme Sonrasi Performanslarinin Değerlendirilmesi Üzerine Bir Araştirma

Öz

Bu çalışmada, talaşlı imalatta yaygın olarak kullanılan parmak frezelerin, bilenerek tekrar kullanılmaları halindeki performansları araştırılmıştır. Bu amaçla, CNC dik işleme merkezinde, AISI 1050 imalat çeliği üzerinden ilk kez kullanılmış olan iki farklı çapta HSS parmak frezeler ile AISI D2 (2080) soğuk iş takım çeliği üzerinden de yine ilk kez kullanılmış olan iki farklı çapta karbür parmak frezeler ile talaş kaldırma işlemleri yapılmıştır. Talaş kaldırma deneyleri, dört farklı kesme hızı, dört farklı ilerleme ve dört farklı kesme derinliği uygulanarak yapılmıştır. Sonrasında, kullanılan bu parmak frezeler, orijinal takım geometrisi dikkate alınarak yeniden bilenmiş ve aynı şartlarda talaş kaldırma deneyleri tekrarlanarak performansları, yeni takımların performansları ile mukayeseli olarak değerlendirilmiştir. Genel olarak bilenmiş takımlardaki aşınma miktarlarının yeni takımlara göre daha yüksek olduğu gözlenmiştir. HSS takımlarda bileme işleminin işleme performansına herhangi bir olumsuz etkisi gözlenmemiştir. Yekpare sementit karbür takımlarda özellikle yüzey kalitesi açısından küçük çaplı takımlar için yeniden bilemenin olumsuz bir etkisi gözlenmezken çaptaki artışa paralel olarak yüzey kalitesindeki beklentilerin izlenmesi kaydı ile yeniden bileme işlemi önerilebilir.

Anahtar Kelimeler

• Kesme Kuvveti
• İşleme performansı
• Yeniden Bileme
• Yüzey Pürüzlülüğü
• Takım Yanak Aşınması

Kaynakça

1. Domaç, H. 2010. Frezeleme İşleminde Kesici Uç Yarıçapı ve Uç Geometrisinin Yüzey Pürüzlülüğü ve Kesme Kuvvetleri Üzerindeki Etkilerinin Araştırılması, Gazi Üniversitesi Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi, Ankara, s. 10.
2. Tonshoff, H. L., Spintig, W., Konig, W., Neises, A. 1994. Machining of Holes Developments in Drilling Technology, Annals of the CIRP, Cilt. 43(2), s. 551-560.
3. Diniz, A. E., Filho, J. C. 1999. Influence of The Relative Positions of Tool And Workpiece on Tool Life, Tool Wear and Surface in The Face Milling Process, Wear, Cilt. 232(1), s. 67-75.
4. Boothroyd, G., Knight, W.A. 1989. Fundamentals of Machining and Machine Tools, Second Edition. Marcel Dekker Inc. Cilt 5, s. 212-222.
5. Ghani, J. A., Choudhury, A., Masjuki, H.H. 2004. Performance of P10 Tin Coated Carbide Tools When End Milling AISI H13 Tool Steel at High Cutting Speed, Journal of Materials Processing Technology, Cilt. 153–154, s. 1062–1066.
6. Budak, E., Altındaş, Y., Armegedo, E.J.A. 1996. Prediction of End Milling Force Coefficients from Orthogonal Cutting Data, ASME J. of Manufacturing Science and Engineering, Cilt. 118, s. 216-224.
7. Korkut, İ., Dönertaş, M.Ö. 2007. The Influence of Feed Rate and Tool-Chip Contact Length During Face Milling, Material & Design, Cilt. 28(1), s. 308-312.
8. Zhang Julie, Z., Chen Joseph, C., Kirby, E.D. 2007. Surface Roughness Optimization in An End-Milling Operation Using the Taguchi Design Method, Journal of Materials Processing Technology, Cilt. 184(1-3), s. 223-239.

9. Gökkaya, H., Sur, G., Dilipak, H. 2006. Kaplamasız Sementit Karbür Kesici Takım ve Kesme Parametrelerinin Yüzey Pürüzlülüğüne Etkisinin Deneysel Olarak İncelenmesi. Pamukkale Üniversitesi Mühendislik Fakültesi Dergisi, Cilt. 12(1), s. 59-64.
10. Güllü, A., Özdemir, A. 2003. Experimentally Determination of The Relationship Between Surfaces Roughness and The Cutting Parameters in Milling of The Prismatic Parts, Gazi University Journal of Science, Cilt. 16(1), s. 127-134.
11. Jawaid, A., Sharif, S., Koksal, S. 2000. Evaluation of Wear Mechanisms of Coated Carbide Tools When Face Milling Titanium Alloy, Journal of materials processing technology, Cilt. 99(1-3), s. 266–274.
12. Chou, Y.K., Song, H. 2001. Hard Turning with Different Nose-Radius Ceramic Tools, SME Tech. Pap. Ser., s. 13-26.
13. Yang, W.H., Tarng, Y.S. 1998. Design Optimization of Cutting Parameters for Turning Operations Based on The Taguchi Method, Journal of Materials Processing Technology, Cilt. 84(1-3), s. 122-129.
14. Kopač, J., Bahor, M., Soković, M. 2002. Optimal Machining Parameters for Achieving the Desired Surface Roughness in Fine Turning of Cold Pre-Formed Steel Workpieces, International Journal of Machine Tools and Manufacture, Cilt. 42(6), s. 707- 716.
15. Choudhury, S.K., Bartarya, G. 2003. Role of Temperature and Surface Finish in Predicting Tool Wear Using Neural Network and Design of Experiments, International Journal of Machine Tools and Manufacture, Cilt. 43(7), s. 747-753.
16. Davim, J.P., Gaitonde, V.N., Karnik, S.R. 2008. Investigations into The Effect of Cutting Conditions on Surface Roughness in Turning of Free Machining Steel by ANN Models, Journal of Materials Processing Technology, Cilt. 205 (1-3), s. 16-23.
17. Jawaid, A., Köksal, S., Sharif, S. 2001. Cutting Performance and Wear Characteristics of PVD Coated and Uncoated Carbide Tools in Face Milling Inconel 718 Aerospace Alloy, Journal of Materials Processing Technology, Cilt. 116 (1), s. 2-9.
18. Rajeev, D., Dinakaran, D., Singh, S.C.E. 2017. Artificial neural network-based tool wear estimation on dry turning processes of AISI 4140 steel using coated carbide tool, Bulletin of the Polish Academy of Sciences, Technical Sciences, Cilt. 65(4), s. 553-559.
19. Sivaiah, P., Chakradhar, D. 2019. Performance Improvement of Cryogenic Turning Process During Machining of 17-4 PH Stainless Steel Using Multi Objective Optimization Techniques, Measurement, Cilt. 136, s. 326-336.
20. Arulkirubakaran, D., Senthilkumar, V., Lomesh Chilamwar, V., Senthil, P. 2019. Performance of Surface Textured Tools During Machining of Al-Cu/Tib2 Composite, Measurement, Cilt. 137, s. 636-646.
21. Shokrani, A.V., Dhokia, Newman S.T. 2017. Hybrid Cooling and Lubricating Technology for CNC Milling of Inconel 718 Nickel Alloy, Procedia Manufacturing, Cilt. 11, s. 625-632.
22. Kara, F. 2018. Optimization of Surface Roughness in Finish Milling of AISI P20+S Plastic-Mold Steel, Materiali in Tehnologije/Materials and Technology, Cilt. 52(2), s. 195–200.
23. Çiftçi, İ., Gökçe, H. 2019. Optimisation Of Cutting Tool and Cutting Parameters in Machining of Molybdenum Alloys Through the Taguchi Method, Journal of the Faculty of Engineering and Architecture of Gazi University, Cilt. 34(1), s. 201-2013.
24. Das, R., Mohanty, S. S., Panigrah, M., Mohanty, S. 2018. Predictive Modelling And Analysis Of Surface Roughness In CNC Milling Of Green Alumina Using Response Surface Method And Genetic Algorithm, IOP Conf. Series: Materials Science and Engineering, s. 410: 1-11.
25. Nghiep, TN, Sarhan, A. A. D., Aoyama, H. 2018. Analysis of tool deflection errors in precision CNC end milling of aerospace Aluminum 6061 T6 alloy, Measurement, Cilt. 125, s. 476-495.
26. Böhler Sert Maden ve Takım Sanayi ve Ticaret A.Ş. 1990. Talaş kaldırma bilgileri, Yeni Karar Yayıncılık, İstanbul, s. 31-42.
27. Şahin, Y. 2000. Talaş kaldırma prensipleri, Nobel Yayın Dağıtım, Ankara, s. 163-170.
28. Şeker, U. 2010. Talaş kaldırma Prensipleri Ders Notları, Ankara.
29. Trent, E.M. 1989. Metal cutting, Butterworths Press, London, s. 1-171.
30. Sandvik Coromant, Modern Metal Cutting, 2008. Sandvikens Tryckeri, Sweden, s. 1-6.
31. Sandvik Coromant, Sandvik Coromant El Kitabı, 2005. Talaşlı İmalat Teknik Kılavuzu. Türkçe Basım, Elanders, İsveç, D5-D9.