Surface Roughness Analysis in Machining of Stainless Steel by Trochoidal Milling under Dry and MQL Cutting Environment

Abstract

Trochoidal milling is a machining technique that enables high-efficiency machining of particularly hard-to-cut materials using a specific tool path at high feed and cutting speeds. This research focused on the impacts of dry and MQL milling on surface roughness (Ra) in trochoidal milling groove opening on AISI 304 stainless steel. Experiments were conducted with a TiAlN-coated carbide end mill using parameters such as variable cutting speed, axial depth of cut (ap), and constant feed. Analysis of variance was used for evaluating the effects of the parameters on surface roughness. While surface roughness increased in dry cutting with increasing ap, it decreased in MQL environment. This result was ascribed to the stable cutting process resulting from the MQL application's reduction of friction along the milling cutter edge and the prevention of BUE formation. Based on the results, the minimum Ra value of 0.386 μm was acquired in the MQL cutting environment at a cutting speed of 150 m/min and a ap of 8 mm. According to Ra measurements from four groove surfaces, the surface roughness obtained in the MQL environment was on average 17.5% lower than in dry cutting. According to the ANOVA results, cutting speed was the most effective parameter in trochoidal milling under dry and MQL environments. These results prove the positive effect of the MQL application in trochoidal milling operations on increasing machining efficiency.

Keywords

• Trochoidal milling
• Minimum quantity lubrication (MQL)
• Surface roughness
• Grooving
• Statistical analysis

Kuru ve MQL Kesme Ortamında Trokoidal Frezeleme ile Paslanmaz Çelik İşlemede Yüzey Pürüzlülüğü Analizi

Öz

Trokoidal frezeleme, özellikle kesilmesi zor malzemelerin belirli bir takım yolu kullanılarak yüksek ilerleme ve kesme hızlarında yüksek verimlilikte işlenmesini sağlayan bir işleme tekniğidir. Bu araştırma, kuru ve MQL frezelemenin AISI 304 paslanmaz çelik üzerindeki trokoidal frezeleme oluğu açılmasında yüzey pürüzlülüğü (Ra) üzerindeki etkilerine odaklanmıştır. Deneyler, değişken kesme hızı, eksenel kesme derinliği (ap) ve sabit ilerleme gibi parametreler kullanılarak TiAlN kaplı karbür uç freze ile gerçekleştirilmiştir. Parametrelerin yüzey pürüzlülüğü üzerindeki etkilerini değerlendirmek için varyans analizi kullanılmıştır. Yüzey pürüzlülüğü kuru kesmede artan ap ile artarken, MQL ortamında azalmıştır. Bu sonuç, MQL uygulamasının freze kenarı boyunca sürtünmeyi azaltması ve BUE oluşumunu engellemesi sonucu oluşan kararlı kesme sürecine bağlanmıştır. Sonuçlara göre, MQL kesme ortamında 150 m/dk kesme hızı ve 8 mm ap ile 0,386 μm'lik minimum Ra değeri elde edilmiştir. Dört oluk yüzeyinden yapılan Ra ölçümlerine göre, MQL ortamında elde edilen yüzey pürüzlülüğü, kuru kesme işlemine göre ortalama %17,5 daha düşüktü. ANOVA sonuçlarına göre, kuru ve MQL ortamlarında trokoidal frezelemede en etkili parametre kesme hızıydı. Bu sonuçlar, trokoidal frezeleme işlemlerinde MQL uygulamasının işleme verimliliğini artırmadaki olumlu etkisini kanıtlamaktadır.

Anahtar Kelimeler

• Trokoidal frezeleme
• Minimum miktarda yağlama (MQL)
• Yüzey pürüzlülüğü
• Kanal açma
• İstatistiksel analiz

Kaynakça

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