Experimental Investigating of the Effects of Cutting Parameters on Thrust Force and Moment in Drilling of Al7SiMg Alloy

Öz

The increasing use of light alloys in engineering applications makes Al–Si–Mg-based casting alloys indispensable for the automotive and aerospace sectors. These alloys stand out with their high castability, mechanical strength, and machinability, and these properties are closely related to the alloy's chemical composition and microstructure. In this context, the Al–7Si–Mg casting alloy stands out as a material that stands out in terms of both structural and manufacturing performance. In this study, the microstructure, mechanical properties, and machinability behavior of the Al–7Si–Mg alloy during drilling were investigated from a comprehensive perspective. Microstructural analyses revealed that the alloy contains brittle intermetallic phases such as β-Al₅FeSi, π-AlSiMgFe, and Mg₂Si within the α-Al matrix, and that these phases play a decisive role in crack formation. Mechanical tests revealed that the alloy exhibited a tensile strength of approximately 110 MPa, a yield strength of 65 MPa, and an elongation at fracture of 2.2%, with a Brinell hardness of 55 HB10. Drilling experiments evaluated the effects of three different cutting speeds (V: 88, 123, and 158 m/min) and three different feed rates (f: 0.04, 0.12, and 0.20 mm/rev) on cutting force and torque. The findings showed that increasing V significantly reduced both force and torque at each f, while increasing f resulted in significant increases in these outputs. Furthermore, significant Built-Up Edge (BUE) and surface layer formation were observed under low speed and high f parameters. However, a V of 158 m/min and a f of 0.04 mm/rev resulted in more broken chip structures.

Anahtar Kelimeler

• Al7SiMg alloy
• Drilling
• Microstructure
• Chip formation
• Built-up edge (BUE)

Al7SiMg Alaşımının Delinmesinde Kesme Parametrelerinin İlerleme Kuvveti ve Moment Üzerindeki Etkilerinin Deneysel İncelenmesi

Öz

Hafif alaşımların artan mühendislik uygulamalarında kullanımı, Al–Si–Mg esaslı döküm alaşımlarını otomotiv ve havacılık sektörleri için vazgeçilmez kılmaktadır. Bu alaşımlar, yüksek dökülebilirlik, mekanik dayanım ve işlenebilirlik özellikleriyle ön plana çıkarken; söz konusu özellikler, alaşımın kimyasal bileşimi ve mikro yapısıyla yakından ilişkilidir. Bu bağlamda, Al–7Si–Mg döküm alaşımı hem yapısal hem de imalat performansları açısından dikkat çeken bir malzeme olarak öne çıkmaktadır. Bu çalışmada, Al–7Si–Mg alaşımının mikroyapı, mekanik özellikler ve delme işlemi sırasındaki işlenebilirlik davranışları çok yönlü biçimde incelenmiştir. Mikroyapı analizleri; alaşımın α-Al matrisi içerisinde β-Al₅FeSi, π-AlSiMgFe ve Mg₂Si gibi gevrek intermetalik fazlar içerdiğini ve bu fazların çatlak oluşumunda belirleyici rol oynadığını göstermiştir. Mekanik testler sonucunda, alaşımın yaklaşık 110 MPa çekme dayanımı, 65 MPa akma dayanımı ve %2,2 kopma uzaması sergilediği; ayrıca Brinell sertlik değerinin 55 HB10 olduğu tespit edilmiştir. Delme deneylerinde üç farklı kesme hızı (88, 123, 158 m/dak) ve üç farklı ilerleme miktarı (0,04; 0,12 ve 0,20 mm/dev) kullanılarak ilerleme kuvveti (Fz) ve moment (Mz) üzerindeki etkiler değerlendirilmiştir. Bulgular, artan kesme hızının her ilerleme seviyesinde hem kuvveti hem torku anlamlı şekilde azalttığını; ilerleme miktarındaki artışın ise bu çıktılarda belirgin artışlara yol açtığını göstermiştir. Ayrıca, düşük kesme hızı ve yüksek ilerleme parametreleri altında belirgin yığıntı talaş (YT) ve yüzeyde katman oluşumu gözlenmiş; buna karşın 158 m/dak kesme hızı ve 0,04 mm/dev ilerleme ile daha kırılgan talaş yapıları elde edilmiştir.

Anahtar Kelimeler

• Al7SiMg alaşımı
• Delme
• Mikro yapı
• Talaş oluşumu
• Yığıntı talaş (YT)

Kaynakça

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