Laminant Kompozitin Cep Frezelenmesinde Yüzey Pürüzlülüğü Ve Boyutsal Tamlığın Değerlendirilmesi

Yıl 2018, , 79 - 100, 31.01.2018

Ali Riza Motorcu , Tuncay Bilge

https://doi.org/10.29130/dubited.324440

Öz

Bu
çalışmada, laminat kompozitler üzerine cep işlemede kontrol faktörlerinin
(takım yolu stratejisi, takım tipi ve malzemesi, kesme hızı, ilerleme miktarı,
kesici takımın yana kayma mesafesi) yüzey pürüzlülüğü ve boyutsal tamlık
üzerindeki ana etkileri, % katkıları ve optimum değerleri Taguchi Metodu, ana
etki grafikleri, Varyans analizi ve Gri İlişkisel Analiz yöntemi kullanılarak
belirlenmiştir. Çalışma sonuçlarına göre, yüzey pürüzlülüğü üzerinde en etkili
parametreler sırasıyla kesici takım geometri ve malzemesi (% 70.90), kesme hızı
(%9.40) ve yana kayma mesafesi (%8.20) olmuştur. Aynı şekilde, boyutsal tamlık
üzerinde de kesici takım tipi ve malzemesinin (%99.35) anlamlı bir etkisi
gözlemlenmiş iken diğer parametrelerin toplam etkisi % 1’in altında kalmıştır.
Hem minimum yüzey pürüzlülüğü ve hem de nominal ölçülere daha yakın boyutsal
tamlıkta cepler elde etmek için kontrol faktörlerinin optimum seviyeleri; TPS2:Doğrusal
cep işleme, Ct3:Yuvarlak uçlu helisel HSS parmak freze, Vc3:350
m/dak, f2:0.011 mm/dev ve SO1:3 mm olarak belirlenmiştir.
Diğer taraftan, kompozit laminatlar üzerine cep işlemede yüzey pürüzlülüğü ve boyutsal
tamlık üzerinde karbür takımların performansı zayıf bulunmuştur.

Anahtar Kelimeler

Laminat kompozit, Cep frezeleme, Boyutsal tamlık, Yüzey pürüzlülüğü, Taguchi metodu

Evaluation of Surface Roughness and Dimensional Accuracy in the Pocket Milling of Laminated Composite

Öz

In this study, the main effects, % additions and optimum values of control factors (tool path strategy, tool type and material, cutting speed, feed rate, step over) on surface roughness and dimensional accuracy were determined by using Taguchi Method, main effect graphs, Variance analysis and Gray Relational Analysis method in pocket machining on laminate composites. According to the study results, the most effective parameters on the surface roughness were cutting tool type and material (70.90%), cutting speed (9.40%) and step over (8.20%), respectively. Likewise, a significant effect of cutting tool type and material (99.35%) was observed on the dimensional accuracy, while the total effect of other parameters remained below 1%. Optimum levels of control factors to achieve both minimum surface roughness and dimensional accuracy closer to the nominal size were determined as TPS2:Linear pocket machining, Ct3:Rounded edge helical HSS end mill, Vc3:350 m/min, f2:0.011 mm/rev and SO1:3 mm. On the other hand, the performance of the solide carbide tools on the surface roughness and dimensional accuracy in pocket milling on the laminated composite was found to be poor.

Anahtar Kelimeler

Laminated composite, Pocket milling, Dimensional accuracy, Surface roughness, Taguchi method, Gray Relation Analysis

Kaynakça

• [1] T. N.Valarmathi, K. Palanikumar and S. Sekar "Modeling of surface roughness in drilling of MDF panels", Applied Mechanics and Materials, vol. 766-767, pp. 831-836, 2015.
• [2] Y. Karpat, O. Bahtiyar and B. Değer, “Mechanistic force modeling for milling of unidirectional carbon fiber reinforced polymer laminates”, International Journal of Machine Tools and Manufacture, vol. 56, pp. 79–93, 2012.
• [3] Y. Karpat, O. Bahtiyar and B. Değer, “Milling Force Modelling of Multidirectional Carbon Fiber Reinforced Polymer Laminates”, Procedia CIRP, vol. 1, pp.460-465, 2012.
• [4] A. Hosokawa, N. Hirose, T. Ueda and T. Furumoto, “High-quality machining of CFRP with high helix end mill”, CIRP Annals - Manufacturing Technology, vol. 63, no. 1, pp.89–92, 2014.
• [5] W. Hintze, M. Cordes and G. Koerkel, “Influence of weave structure on delamination when milling CFRP”, Journal of Materials Processing Technology, vol. 216, pp.199–205, 2015.
• [6] S.C. Han, Y. Chen, J.H. Xu and J.W. Zhou, "Experimental study of tool wear in milling multidirectional CFRP laminates", Materials Science Forum, vol. 770, pp. 276-280, 2014.
• [7] W. Hintze and D. Hartmann, “Modeling of delamination during milling of unidirectional CFRP”, Procedia CIRP, vol. 8, pp. 444-449, 2013.
• [8] O. Pecat, R. Rentsch and E. Brinksmeier, “Influence of milling process parameters on the surface integrity of CFRP”, Procedia CIRP, vol. 1, pp. 466-470, 2012.
• [9] M.H. El-Hofy, S.L. Soo, D.K. Aspinwall, W.M. Sim, D. Pearson and P. Harden, “Factors affecting workpiece surface integrity in slotting of CFRP”, Procedia Engineering, vol. 19, pp. 94-99, 2011.
• [10] M. Nurhaniza, M.K.A.M. Ariffin, F. Mustapha and B.T.H.T. Baharudin, “Analyzing the effect of machining parameters setting to the surface roughness during end milling of CFRP-Aluminium composite laminates”, International Journal of Manufacturing Engineering, vol. 2016, pp. 1-9, 2016.
• [11] H.M. Ali, A. Iqbal and L. Liang “A comparative study on the use of drilling and milling processes in hole making of GFRP composite”, Sadhana, vol. 38, no. 4, pp. 743–760, 2013.
• [12] A.I. Azmi, R.J.T. Lin and D. Bhattacharyya, “Experimental study of machinability of GFRP composites by end milling”, Materials and Manufacturing Processes, vol. 27, no. 10, pp. 1045-1050, 2010.
• [13] M. Iliescu, P. Spânu and M. Costoiu, “Glass fibres reinforced polymeric composites - Statistic models of surface roughness”, Materiale Plastice, vol. 44, no. 4, pp.365-369, 2007.
• [14] N. Naresh, K. Rajasekhar and P. VijayaBhaskara Reddy, “Parametric analysis of GFRP composites in CNC milling machine using Taguchi method”, IOSR Journal of Mechanical and Civil Engineering, vol. 6, no. 1, pp. 102-111, 2013.
• [15] P.P. Raj and A.E. Perumal, “Taguchi analysis of surface roughness and delamination associated with various cemented carbide K10 end mills in milling of GFRP”, Journal of Engineering Science and Technology Review,vol. 3, no. 1, pp. 58-64, 2010.
• [16] G. Goli, M. Fioravanti, R. Marchal, L. Uzielli and S. Busoni, “Up-milling and down-milling wood with different grain orientations – the cutting forces behaviour”, European Journal of Wood and Wood Products, vol. 68, no. 4, pp. 385–395, 2010.
• [17] S.D. Sofuoglu, “Determination of optimal machining parameters of massive wooden edge glued panels which is made of Scots pine (Pinus sylvestris L.) using Taguchi design method”, European Journal of Wood and Wood Products, vol. 75, no. 1, pp. 33–42, 2017.
• [18] A. Petrovic, L. Lukic, S. Ivanovic and A. Pavlovic, “Optimisation of tool path for wood machining on CNC machines”, Proc IMechE Part C: J Mechanical Engineering Science, vol. 231, no. 1, pp. 72-87, 2017.
• [19] B. Pałubicki and T. Rogoziński, “Efficiency of chips removal during CNC machining of Particleboard” Wood Research, vol. 61, no. 5, pp. 811-818, 2016. [20] G.D. Babu, K.S. Babu and B.U.M. Gowd, “Effect of machining parameters on milled natural fiberreinforced plastic composites”, Journal of Advanced Mechanical Engineering, vol. 1, pp.1-12, 2013.
• [21] T. Bilge, A.R. Motorcu ve A. Ivanov “Kompakt laminat kompozit malzemenin tungsten karbür takımlarla delinmesinde delaminasyon faktörünün değerlendirilmesi”, Pamukkale Üniversitesi Mühendislik Bilimleri Dergisi, vol. 6, no. 3, pp.180-192, 2017.
• [22] T. Bilge, A.R. Motorcu ve A. Ivanov, “Kompakt laminant kompozitin delinmesinde yüzey pürüzlülüğünün değerlendirilmesi”, 17. Uluslararası Makina Tasarım ve İmalat Kongresi, Bursa, Türkiye, 2016, ss. 1-15.
• [23] Anonim, (3 Temmuz 2017). [Online]. Erişim: http://www.asdlaminat.com/dosya/tds/compact-laminat-teknik-degerler-tr.pdf.
• [24] Anonim, (3 Temmuz 2017). [Online]. Erişim: https://drive.google.com/a/comu.edu.tr/file/d/0B9ho0 dpYVTFONG9hdzJYelVNNlE/view.
• [25] R.K. Roy, A Primer on the Taguchi Method. Competitive Manufacturing Series, 1st ed., New York, USA: Van Nostrand Reinhold, 1990, pp: 25-75.
• [26] E. Yılmaz ve F. Güngör, “Gri ilişkisel analiz yöntemine göre farklı sertliklerde optimum takım tutucusunun belirlenmesi”, 2. Ulusal Tasarım İmalat ve Analiz Kongresi, Balıkesir, Türkiye, 2010, ss. 1-9.