Optimization of Cutting Tool Wear When Milling 6061-T651 Aluminum Alloy with Coated Inserts

Abstract

In this study, the effects of cutting parameters on cutting tool wear were investigated by performing surface milling on 80x80x30 mm 6061-T651 aluminum alloy. Inserts with three different coatings (TiN-TiCN-Al2O3 coated by CVD technique, TiALN-NANO coated by PVD technique, and ALTiN coated by PVD technique), three different cutting speeds (250, 350, and 450 m/min), and three different feed rates (0.15, 0.30, and 0.45 mm/tooth) were used for the face milling process. The experiments were conducted in a dry setting and the depth of cut was kept constant at 0.5 mm in all experiments. The Taguchi method was used for the design and optimization of the experiments; Taguchi L9 (33) orthogonal array was selected and 9 experiments were conducted. Tool flank wear was measured after each run. The obtained results were optimized and evaluated using variance analysis (ANOVA), 3-D graphs, and regression method. After the measurements, cutting parameters were optimized successfully using the Taguchi method to achieve minimum tool wear. As a result of the Taguchi analysis, the optimum cutting conditions obtained for minimum wear value were determined as the TiN-TiCN-Al2O3 coated insert, 450 m/min cutting speed, and 0.30 mm/tooth feed rate. 

Keywords

• AA 6061-T651
• Face milling
• Cutting tool wear
• Optimization
• Taguchi method

Alüminyum 6061-T651 Alaşımının Kaplamalı Kesici Uçlarla Frezelenmesinde Kesici Takım Aşınmasının Optimizasyonu

Abstract

Bu çalışmada 80x80x30 mm ebatlarında alüminyum 6061-T651 alaşımına yüzey frezeleme işlemleri gerçekleştirilerek kesme parametrelerinin kesici takım aşınması üzerine etkileri araştırılmıştır. Yüzey frezeleme işlemi için; üç farklı kaplamaya sahip kesici uç (CVD tekniği ile TiN-TiCN-Al2O3 kaplanmış, PVD tekniği ile TiALN-NANO kaplanmış ve PVD tekniği ile ALTiN kaplanmış) üç farklı kesme hızı (250, 350 ve 450 m/dak) ve üç farklı ilerleme oranı (0.15, 0.30 ve 0.45 mm/diş) kullanılmıştır. Deneyler kuru şartlarda yürütülüp kesme derinliği 0.5 mm olarak tüm deneylerde sabit tutulmuştur. Deneysel tasarım ve optimizasyon için Taguchi metodu kullanılmış, Taguchi L9 (33) ortogonal dizisi seçilerek 9 deney yürütülmüştür. Her bir deney sonrası takım yan yüzey aşınmaları ölçülmüştür. Deneyler sonunda elde edilen değerler optimize edilmiş, varyans analizi (ANOVA), üç boyutlu grafikler ve regresyon metodu kullanılarak değerlendirilmiştir. Deneyler sonrası en düşük takım aşınması için kesme parametreleri, Taguchi metoduyla başarılı bir şekilde optimize edilmiştir. Taguchi analizi sonucu minimum aşınma değeri için elde edilen optimum kesme şartları; TiN-TiCN-Al2O3 kaplamalı kesici uç, 450 m/dak kesme hızı ve 0.30 mm/diş ilerleme oranı olarak bulunmuştur. 

Keywords

• AA 6061-T651
• Yüzey frezeleme
• Kesici uç aşınması
• Optimizasyon
• Taguchi metodu

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