Investigation of the Effect on Tool Wear of Nanoparticle Added Lubrication in Milling of Waspaloy Super Alloy

Abstract

The use of cutting fluids is of great importance in order to increase the machinability efficiency of difficult-tocut materials such as Waspaloy. However, the use of extreme cutting fluid is concerned by manufacturers in such issues as the environment, human health and production cost. One of the alternative methods to minimize these concern is the Minimum Quantity Lubrication (MQL) system. Moreover, researches are continued to reduce the amount of cutting fluids. In this study, it was intended to further reduce the amount of cutting fluid so nanoparticle was added to the contents of the cutting fluid in the MQL system. For this purpose, Waspaloy milling experiment were carried out under dry, MQL and NanoMQL (1 vol% Al2O3) conditions and the differences between cooling/lubrication methods have been revealed. Tool wear was selected as output parameter during milling experiments. Three different cutting speeds (20, 40, 60 m/min) and three different feed rates (0.05, 0.10 and 0.15 mm/rev) were selected as cutting parameters. According to the analysis of the experiment results, the optimum wear value was 20 m/min cutting speed, 0.05 mm/rev feed rate and NanoMMY cutting conditions.

Keywords

• Waspaloy,Tool wear,Nano MQL

Waspaloy Süper Alaşımının Frezelenmesinde Nanopartikül Katkılı Yağlamanın Takım Aşınması Üzerindeki Etkisinin Araştırılması

Abstract

Waspaloy gibi işlenebilirliği zor malzemelerin işleme verimliliğini artırmak için, kesme sıvısı kullanımı büyük önem taşımaktadır. Ancak, aşırı kesme sıvısı kullanımı çevre, çalışan sağlığı ve üretim maliyeti gibi konularda imalatçıları endişelendirmektedir. Bu endişeleri minimuma indirmek için kullanılan alternatif yöntemlerden birisi de Minimum Miktarda Yağlama (MMY) sistemidir. Bununla beraber, kesme sıvısı miktarının azaltılması için çalışmalar artarak devam etmektedir. Bu çalışmada, MMY sisteminde kullanılan kesme sıvısının içerisine nanopartikül katkı maddesi eklenerek kullanılan kesme sıvısı miktarını daha da azaltmak amaçlanmıştır. Bu amaç doğrultusunda, Waspaloy süper alaşımı; kuru, MMY ve NanoMMY (hacimce %1 Al2O3) şartları altında işlenmiş ve soğutma/yağlama yöntemleri arasındaki farklar ortaya konulmuştur. Frezeleme deneyleri esnasında çıktı olarak takım aşınması seçilmiştir. Kesme parametresi olarak ise üç farklı kesme hızı (20, 40, 60 m/dak) ve üç farklı ilerleme hızı (0,05-0,10 ve 0,15 mm/dev) seçilmiştir. Deney sonuçlarının analizine göre, optimum aşınma değeri 20 m/dak kesme hızı, 0,05 mm/dev ilerleme ve NanoMMY şartları altında gerçekleşmiştir.

Keywords

• Waspaloy,Takım aşınması,NanoMMY

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