Effect of machining parameters on surface quality of w-edmed Ti6Al4V alloy in ultrasonic assisted magnetic abrasive finishing technique

Öz

Components used in engineering applications are expected to have superior mechanical properties, as well as geometric properties such as tolerance, accuracy and surface quality. Traditional manufacturing methods are insufficient to meet these expectations. It has become mandatory to use nontraditional manufacturing methods especially in the difficult to cut materials. In this study, Ti6Al4V alloy, which is frequently used in areas where high technology is used such as aviation, space and medical, was machined by electrical discharge machining (EDM) method and the surface qualities of the machined surfaces were improved by magnetic abrasive finishing (MAF) method. In the study, the effects of ultrasonic support, machining time, SiC abrasive size, spindle speed and magnetic field amount parameters on surface roughness improvement rate (SRIR) and material removal rate (MRR) were investigated experimentally. The experimental results obtained were evaluated statistically by variance analysis method. As a result of the study, it was determined that in MAI and UDMAI methods, the surface qualities were improved by 36% and 57%, respectively and these rates increased up to 81% and 90%, respectively, under appropriate test conditions. On the other hand, MRR values were measured as 4.95 mg/min and 5.74 mg/min, respectively, for the MAI and UDMAI methods. When MAI and UDMAI methods were compared, it was determined that ultrasonic assist had a positive effect of 58% on average in terms of SRIR values and 15% on average in terms of MRR.

Anahtar Kelimeler

• Wire-EDM
• Ultrasonic assisted magnetic abrasive finishing
• Ti6Al4V
• Material removal rate
• Surface quality

Proje Numarası

07/2020-04

Ultrasonik destekli manyetik aşındırıcılarla işleme yönteminde işleme parametrelerinin tel erozyon ile işlenmiş Ti6Al4V alaşımının yüzey kalitesi üzerindeki etkileri

Öz

Mühendislik uygulamalarında kullanılan bileşenlerin üstün mekanik özelliklere sahip olmasının yanı sıra sınırları önceden belirlenmiş geometrik ve boyutsal toleranslar ile yüzey kalitesi kıstaslarını da karşılaması gerekmektedir. Bu beklentilerin karşılanması için geleneksel imalat yöntemleri genelde yetersiz kalmaktadır. Özellikle talaşlı imalatla şekillendirilmesi zor malzemelerin işlenmesinde geleneksel olmayan imalat yöntemlerinin kullanılması zorunlu hale gelmiştir. Bu çalışmada özellikle havacılık uzay ve medikal gibi yüksek teknolojinin kullanıldığı alanlarda sıklıkla kullanılan Ti6Al4V alaşımı, elektro erozyonla işleme (EEİ) yöntemi aracılığıyla işlenmiş ve işlenen yüzeylerin yüzey kaliteleri manyetik aşındırıcılarla işleme (MAİ) yöntemiyle iyileştirilmiştir. Çalışmada, ultrasonik destek, işleme süresi, SiC aşındırıcı boyutu, devir sayısı ve manyetik alan miktarı parametrelerinin, yüzey pürüzlülüğü iyileşme oranı (YPİO) ve talaş kaldırma oranı (TKO) üzerindeki etkileri deneysel olarak araştırılmıştır. Elde edilen deneysel sonuçlar varyans analizi yöntemi ile istatistiksel olarak değerlendirilmiştir. Çalışma sonucunda yüzey kalitelerinin MAİ ve UDMAİ yöntemlerinde ortalama olarak sırasıyla %36 ve %57 oranlarında iyileştirildiği ve bu oranların uygun deney koşullarında sırasıyla %81 ve %90 değerlerine kadar yükseldiği tespit edilmiştir. Öte yandan TKO değerleri MAİ ve UDMAİ yöntemleri için ortalama olarak sırasıyla 4,95 mg/min ve 5,74 mg/min olarak ölçülmüştür. MAİ ve UDMAİ yöntemleri karşılaştırıldığında ise ultrasonik desteğinin YPİO değerleri açısından ortalama % 58, TKO açısından ortalama % 15 oranında olumlu etki yaptığı tespit edilmiştir.

Anahtar Kelimeler

• Tel erozyonla işleme
• Ultrasonik destekli manyetik aşındırıcılarla işleme
• Ti6Al4V
• Talaş kaldırma oranı
• Yüzey kalitesi

Destekleyen Kurum

Gazi Üniversitesi Bilimsel Araştırma Projeleri Birimi

Proje Numarası

07/2020-04

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