Effect of Processing Parameters on Cutting Torque in Boring of AISI P20 Plastic Mold Steel on Vertical Machining Machine

Öz

AISI P20 plastic mold steel is a material generally used in the mold industry. In mold manufacturing, quality holes are needed because continuity of product quality, high repetitive work, and maximum mold life are required. Additionally, boring tools are used in the manufacture of engine block cylinder housings in the automotive industry. Boring operations play a vital role in obtaining the final quality of pre-drilled holes. The cutting insert of the boring tool contacts the hole wall at a single position relative to the hole axis. This situation causes the cutting torque to result in the highest force in the boring process. Therefore, one of the most critical indicators of hole quality is boring torque. The aim of the present study is to deeply analyze the impacts of coating type, cutting edge radius, feed rate, cutting speed, and radial depth of cut parameters on the boring torque in the precision boring process of AISI P20 material on a vertical machining machine. For this purpose, graphics, Taguchi, and Anova methods were used. As a result, while the radial depth of cut was determined as the most effective parameter on the boring torque, the coated cutting insert produced lower torque values. As a result of the calculated regression equations, an R2 value of 97.47% was obtained.

Anahtar Kelimeler

• Boring
• torque
• optimization
• Taguchi
• Anova
• regression

AISI P20 Plastik Kalıp Çeliğinin Dik İşleme Tezgahında Baralanmasında İşleme Parametrelerinin Kesme Torkuna Etkisi

Öz

AISI P20 plastik kalıp çeliği, genellikle kalıp sektöründe kullanılan bir malzemedir. Kalıp imalatında ise ürün kalitesinin sürekliliği, yüksek tekrarlı çalışma ve maksimum kalıp ömrü gerektiğinden kaliteli deliklere ihtiyaç bulunmaktadır. Ayrıca otomotiv sektöründe motor bloğu silindir yuvalarının imalatında baralar kullanılmaktadır. Önceden delinmiş deliklerin nihai kalitesinin elde edilmesinde baralama operasyonları önemli bir yer tutmaktadır. Delik eksenine göre baranın kesici ucu tek noktada delik duvarı ile temas halindedir. Bu durum ise baralama işleminde kesme torkunun en yüksek kuvvet olarak sonuçlanmasına neden olmaktadır. Dolayısıyla delik kalitesinin en önemli göstergelerinden birisi baralama torkudur. Mevcut çalışmada AISI P20 malzemesinin dik işleme tezgahında hassas baralanması işleminde kaplama tipi, kesici uç radüsü, radyal kesme derinliği, kesme hızı ve ilerleme miktarı parametrelerinin baralama torkuna etkilerinin derinlemesine araştırılması amaçlanmıştır. Bunun için grafikler, Taguchi ve Anova yöntemleri kullanıldı. Sonuç olarak baralama torku üzerinde en etkili parametre olarak radyal kesme derinliği tespit edilirken, kaplamalı kesici uç daha düşük tork değerleri meydana getirmiştir. Hesaplanan regresyon eşitlikleri sonucu %97,47 oranında bir R2 değeri elde edilmiştir.

Anahtar Kelimeler

• Baralama
• tork
• optimizasyon
• Taguchi
• Anova
• regresyon

Kaynakça

1. Kayır Y. and Süzgünol M., Optimization of cutting parameters for drilling AISI P20 die mold alloy steel with Taguchi and GRA methods. Gazi University Journal of Science, 31(3): (2018) 898-910.
2. [2] Stoić A., Kopač J., and Cukor G., Testing of machinability of mould steel 40CrMnMo7 using genetic algorithm. Journal of materials processing technology, 164: (2005) 1624-1630.
3. [3] Zeilmann R.P., Nicola G.L., Vacaro T., Teixeira C.R., and Heiler R., Implications of the reduction of cutting fluid in drilling AISI P20 steel with carbide tools. The International Journal of Advanced Manufacturing Technology, 58: (2012) 431-441.
4. [4] Slamani M., Mayer R., Balazinski M., and Engin S., Identification and compensation of dynamic scale mismatches in high-speed end mill boring trajectory on CNC machines. J. Manuf. Sci. Eng., 132(034501): (2010)
5. [5] Lazoglu I., Atabey F., and Altintas Y., Dynamics of boring processes: Part III-time domain modeling. International journal of machine tools and manufacture, 42(14): (2002) 1567-1576.
6. [6] Lacerda H.B. and Siqueira I.L., Blade geometry effects on the boring of valve seats of internal combustion engines. The International Journal of Advanced Manufacturing Technology, 63: (2012) 269-280.
7. [7] Del Taglia A. and Tani G., A method for measuring cutting forces in boring operations. International Journal of Machine Tool Design and Research, 22(1): (1982) 23-30.
8. [8] Arsuaga M., de Lacalle L.L., Lobato R., Urbikain G., and Campa F. Effect of centrifugal forces on dimensional error of bored shapes. in AIP Conference Proceedings. 2012. American Institute of Physics

9. [9] Parsian A., Stability Prediction of Multiple-Teeth Boring Operations. 2013
10. [10] Atabey F., Lazoglu I., and Altintas Y., Mechanics of boring processes—Part I. International journal of machine tools and manufacture, 43(5): (2003) 463-476.
11. [11] Katsuki A., Onikura H., Sajima T., Takei T., and Thiele D., Development of a high-performance laser-guided deep-hole boring tool:: Optimal determination of reference origin for precise guiding. Precision engineering, 24(1): (2000) 9-14.
12. [12] Katsuki A., Onikura H., Sajima T., Mohri A., Moriyama T., Hamano Y., and Murakami H., Development of a practical high-performance laser-guided deep-hole boring tool: improvement in guiding strategy. Precision Engineering, 35(2): (2011) 221-227.
13. [13] Atabey F., Lazoglu I., and Altintas Y., Mechanics of boring processes—Part II—multi-insert boring heads. International journal of machine tools and manufacture, 43(5): (2003) 477-484.
14. [14] Slamani M., Mayer R., Balazinski M., Carrier B., and Engin S., Improvement to high-speed end mill boring accuracy by a simple compensation strategy. Machining science and technology, 16(1): (2012) 1-19.
15. [15] Valdivielso F., Instrumentation and Control Methodology For Zero Defect Manufacturing In Boring Operations. Annals of Daaam & Proceedings, 23(1): (2012)
16. [16] Barzegar R., Mahboubkhah M., Zakeri V., Matin R., HOSSEINGHOLI P.H., and ABDOLLAHZADEH B.F., Finite Element Prediction on the Machining Stability of Boring Machine with Experimental Verification. (2015)
17. [17] Akdulum A., Süzgünol M., and Kayir Y., Prediction of feed force with machine learning algorithms in boring of AISI P20 plastic mold steel. Materials Today Communications, 41: (2024) 110704.
18. [18] Cheng H., Zhao J., Sun R., Liu S., and Yang Z., Finish boring process of hard alloy cutter based on electrostatic cooling-aided machining. The International Journal of Advanced Manufacturing Technology, 111: (2020) 2999-3013.
19. [19] Zhou H., Yang W., Sun L., Jing X., Li G., and Cao L., Reliability optimization of process parameters for marine diesel engine block hole system machining using improved PSO. Scientific reports, 11(1): (2021) 21983.
20. [20] Dağli H., Baralama operasyonunda kesme şartlarının ve kesici takım kaplama tipinin etkisinin araştırılması ve şartlarının optimizasyonu. 2020, Fen Bilimleri Enstitüsü
21. [21] Demirer E. and Kayır Y., Analysis By Taguchi and ANOVA Methods For The Effect Of The Cutting Tool Height Adjustment On Cutting Forces In Turning AISI304 Stainless Steel Material. Gazi Journal of Engineering Sciences (GJES)/Gazi Mühendislik Bilimleri Dergisi, 8(1): (2022)
22. [22] Kurt M., Bagci E., and Kaynak Y., Application of Taguchi methods in the optimization of cutting parameters for surface finish and hole diameter accuracy in dry drilling processes. The International Journal of Advanced Manufacturing Technology, 40: (2009) 458-469.
23. [23] Başar G. and Kahraman F. Analysis and Optimization of Ball Burnishing Process Parameters of AA 7075 Aluminium Alloy with Taguchi Method. in International Advanced Researches & Engineering Congress 2017 Proceeding Book. 2017. Dr. R. HALICIOGLU
24. [24] Adin M.Ş., İşcan B., and Baday Ş., Optimization of welding parameters of AISI 431 and AISI 1020 joints joined by friction welding using taguchi method. Bilecik Şeyh Edebali Üniversitesi Fen Bilimleri Dergisi, 9(1): (2022) 453-470.
25. [25] Kafkas F., Gürbüz H., and Şeker U., Analysis of The Effect of Tool Geometry and Machining Parameters on Surface Integrity Properties in Turning of AISI 316L Stainless Steel by Taguchi Method. Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji, 10(3): (2022)
26. [26] Akdulum A. and Kayır Y., Investigation of the effect of u drills with different properties on thrust force, torque and spindle load. Politeknik Dergisi, 26(1): (2023) 387-400.
27. [27] Siyambaş Y., Bayraktar Ş., and Turgut Y., Investigation of the effects of cutting parameters on diameter deviation in drilling of HSLA steel. Turkish Journal of Electromechanics & Energy, 2(1): (2017) 3-8.
28. [28] Ucun İ., 3D finite element modelling of drilling process of Al7075-T6 alloy and experimental validation. Journal of Mechanical Science and Technology, 30: (2016) 1843-1850.
29. [29] Çaydaş U. and Çelik M., AA 7075-T6 alaşımının delinmesinde kesme parametrelerinin yüzey pürüzlülüğü, takım sıcaklığı ve ilerleme kuvvetine etkilerinin araştırılması. Politeknik Dergisi, 20(2): (2017) 419-425.
30. [30] Akdulum A. and Kayır Y., Farklı özelliklere sahip U matkaplar ile AA2024-T351’in delinmesinde çaptan sapma, dairesellik ve silindirikliğin incelenmesi. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 39(2): (2024) 1167-1178.