Al-30Zn Alaşımının Delinmesinde Yüzey Cevap Metodu (YCM) Kullanarak İlerleme Kuvveti ve Yüzey Pürüzlülüğünün Optimizasyonu

Yıl 2020, Cilt: 10 Sayı: 3, 804 - 813, 15.07.2020

Şenol Bayraktar Ali Paşa Hekimoğlu

https://doi.org/10.17714/gumusfenbil.672576

Öz

Bu
çalışmada kokil kalıba döküm yöntemi ile Al-30Zn alaşımı üretilmiştir. Sertlik,
çekme mukavemeti ve alaşımın kopma uzaması değerleri belirlendikten sonra delme
testleri yapıldı. Alaşım külçesinden 80x50x20 mm boyutlarında iş parçası
hazırlanmış ve 8 mm çaplı, 30° helis ve 118° uç açılı kaplamasız HSS (High
speed steel) matkaplarla delme testleri yapılmıştır. Delme testleri, istatistiksel
analiz yazılımından elde edilen yüzey cevap metodu (RSM) deneysel tasarımına
göre yapılmıştır. Bağımsız değişkenler, kesme hızı (600-900-1200 dev/dak) ve
ilerleme miktarı (0.05-0.15-0.25 mm/dev), bağımlı değişkenler ise itme kuvveti
ve yüzey pürüzlülüğü olarak tanımlanmıştır. Deney sonuçlarına göre bağımsız
değişkenlerin bağımlı değişkenler üzerindeki istatistiksel etkisi ANOVA ile
analiz edilmiş ve optimum kesme parametreleri belirlenmiştir. Buna göre, itme
kuvveti ve yüzey pürüzlülüğü üzerinde en etkili bağımsız değişkenlerin
sırasıyla ilerleme miktarı ve kesme hızı olduğu gözlenmiştir. Ayrıca minimum
hedef fonksiyonuna göre optimum kesme şartları 1200 dev/dak kesme hızı ve 0.05
mm/dev ilerleme miktarı olarak belirlenmiştir. Doğrulama testleri ile istatistiksel
sonuçların optimum kesme şartlarına bağlı olarak oldukça uyumlu olduğu tespit
edilmiştir.

Anahtar Kelimeler

Delme, Optimizasyon, Yüzey Cevap Metodu, Yüzey Pürüzlülüğü, İtme Kuvveti

Optimization of Thrust Force and Surface Roughness Using Response Surface Methodology (RSM) in Drilling of Al-30Zn Alloy

Öz

In
this study, Al-30Zn alloy was produced by permanent mold casting method.
Drilling tests were performed after the values of hardness, tensile strength
and elongation to fracture of the alloy were determined. 80x50x20 mm in
dimensions workpiece was prepared from alloy ingot and drilling tests were
performed with 8 mm diameter, 30° helix and 118°-point angle uncoated HSS (High
speed steel) drills. Drilling tests were performed according to the
experimental design obtained in response surface methodology (RSM) statistical
analysis software. Independent variables were defined as cutting speed
(600-900-1200 rev/min) and feed rate (0.05-0.15-0.25 mm/rev), while dependent
variables were defined as thrust force and surface roughness. According to the
experimental results, the statistical effect of independent variables on
dependent variables was analyzed with ANOVA and optimum cutting parameters were
determined. Accordingly, it was observed that the most effective independent
variables on thrust force and surface roughness were feed rate and cutting
speed, respectively. In addition, optimum cutting conditions according to
minimum goal function were determined as cutting speed of 1200 rev/min and feed
rate of 0.05 mm/rev. It was found that validation tests and statistical results
were quite compatible depending on optimum cutting conditions.

Anahtar Kelimeler

Drilling, Optimization, Response Surface Methodology, Surface Roughness, Thrust Force

Kaynakça

• Acır, A., Turgut, Y., Übeyli, M., Günay, M., Şeker, U., 2009. A study on the Cutting Force in Milling of Boron Carbide Particle Reinforced Aluminium Composite. Science and Engineering of Composite Materials, 16(3), 187-196.
• Arunachalam, R.M., Mannan, M.A., Spewage, A.C., 2004. Residual Stress and Surface Roughness When Facing Age Hardened Inconel 718 with Cbn and Ceramic Cutting Tools. International Journal of Machine Tools and Manufacture, 44(9), 879-887.
• Bahçe, E., Özdemir, B., 2019. Investigation of the Burr Formation During the Drilling of Free-Form Surfaces in Al 7075 Alloy. Journal of Materials Research and Technology, 8(5), 4198-4208.
• Barnhurst, R.J., 1990. Designing Zinc Alloy Bearings. Journal of Materials Engineering, 12(4), 279-285.
• Barnhurst, R.J., Farge, J.C., 1988. Study of the Bearing Characteristics of Zinc-Aluminum (ZA) Alloys. Canadian Metallurgical Quarterly, 27(3), 225-233.
• Bayraktar, Ş., Afyon, F., 2020. Machinability properties of Al–7Si, Al–7Si–4Zn and Al–7Si–4Zn–3Cu alloys. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 42(4), 1-12.
• Bayraktar, Ş., Çamkerten, Ç., Salihoğlu, N., 2020. Bakır ve Silisyum İlavelerinin Al-25Zn Alaşımının CVD-Al2O3 Kaplamalı Takımlarla Tornalanmasında İşlenebilirliğe Etkisinin İncelenmesi. Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji, 8(1), 79-93.
• Bayraktar, Ş., Hekimoğlu, A.P., Turgut, Y., Hacıosmanoğlu, M., 2017. Effect of Different Cutting Tools on Machinability of the Al-5Zn Alloy, 2nd International Symposium on Industrial Design Engineering (ISIDE), Nevşehir, Turkey, 1-9.
• Bayraktar, Ş., Turgut, Y., 2016. Investigation of the Cutting Forces and Surface Roughness in Milling Carbon-Fiber-Reinforced Polymer Composite Material. Materials and Technology, 50(4), 591-600.
• Bermudo, C., Trujillo, F.J., Herrera, M., Sevilla, L., 2017. Parametric Analysis of the Ultimate Tensile Strength in Dry Machining of UNS A97075 Alloy. Procedia Manufacturing, 13, 81-88.
• Bican, O., Savaşkan, T., 2010. Influence of Test Conditions on the Lubricated Friction and Wear Behaviour of Al-25Zn-3Cu Alloy. Tribology Letters, 37(2), 175-182.
• Bouacha, K., Yallese, M.A., Mabrouki, T., Rigal, J.F., 2010. Statistical Analysis of Surface Roughness and Cutting Forces Using Response Surface Methodology in Hard Turning of AISI 52100 Bearing Steel with CBN Tool. International Journal of Refractory Metals and Hard Materials, 28(3), 349-361.
• Bouzid, L., Yallese, M.A., Chaoui, K., Mabrouki, T., Boulanouar, L., 2015. Mathematical Modeling for Turning on AISI 420 Stainless Steel Using Surface Response Methodology, Proceedings of the. Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 229(1), 45-61.
• Chabbi, A., Yallese, M.A., Nouioua, M., Meddour, I., Mabrouki, T., Girardin, F., 2017. Modeling and Optimization of Turning Process Parameters During the Cutting of Polymer (POMC) Based on RSM, ANN, and DF Methods. International Journal of Advanced Manufacturing Technology, 91(5-8), 2267-2290.
• Çiçek, A., Kıvak, T., Ekici, E., 2015. Optimization of Drilling Parameters Using Taguchi Technique and Response Surface Methodology (RSM) in Drilling of AISI 304 Steel with Cryogenically Treated HSS Drills. Journal of Intelligent Manufacturing, 26(2), 295-305.
• Delneuville, P., 1985. Tribological Behaviour of Zn-Al Alloys (ZA27) Compared with Bronze When Used as a Bearing Material with High Load and Very Low Speed. Wear, 105(4), 283-292.
• Dikshit, M.K., Puri, A.B., Maity, A., 2017. Modelling and Application of Response Surface Optimization to Optimize Cutting Parameters for Minimizing Cutting Forces and Surface Roughness in High-Speed, Ball-End Milling of Al 2014-T6. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 39(12), 5117-5133.
• Gervais, E., Levert, H., Bess, M., 1980. The Development of a Family of Zinc-Based Foundry Alloys. American Foundrymen’s Society Transaction, 88, 183-194.
• Haiyan, W., Xuda, Q., 2016. A Mechanistic Model for Cutting Force in Helical Milling of Carbon Fiber-Reinforced Polymers. International Journal of Advanced Manufacturing Technology, 82(9-12), 1485-1494.
• Hekimoğlu, A.P., Bayraktar, Ş., Turgut, Y., 2018. Investigation of the Effect of Cutting Speed and Feed Rate on Machining of the Al-35Zn Alloy, 2nd International Symposium on Innovative Approaches in Scientific Studies (ISAS), Samsun, Turkey, 77-83.
• Hekimoğlu, A.P., Savaşkan, T., 2018. Lubricated Wear Characteristics of Zn–15Al–3Cu–1Si Alloy and SAE 660 Bronze. Journal of the Faculty of Engineering and Architecture of Gazi University, 33(1), 145-154.
• Hekimoğlu, A.P., Savaşkan, T., 2016. Effects of Contact Pressure and Sliding Speed on the Unlubricated Friction and Wear Properties of Zn-15Al-3Cu-1Si Alloy. Tribology Transactions, 59(6), 1114-1121. Hekimoğlu, A.P., Turan, Y.E., 2019. Effect of Zinc Content on the Microstructure and Mechanical Properties of the Al-(5-50)Zn Alloys. Gümüşhane University Journal of Science and Technology Institute, 9(1), 16-25, (2019).
• Kao, J.Y., Hsu, C.Y., Tsao, C.C., 2019. Experimental Study of Inverted Drilling Al-7075 Alloy. International Journal of Advanced Manufacturing Technology, 102(9-12), 3519–3529.
• Kıvak, T., Ekici, E., Uzun, G., 2016. The Experimental and Statistical Investigation of The Effects of Cutting Parameters and Coating Materials on The Machinability of Hadfield Steel. Gazi University Journal of Science, 29(1), 9-17.
• Kilic, D., Ebegil, M., Bayrak, H., Ozkaya, B., Avsar, B.A., 2019. Optimization of Multi Responses Using Data Envelopment Analysis: The Application in Food Industry. Gazi University Journal of Science, 32(3), 1083-1090.
• Kyratsis, P., Markopoulos, A., Efkolidis, N., Maliagkas, V., Kakoulis, K., 2018. Prediction of Thrust Force and Cutting Torque in Drilling Based on the Response Surface Methodology. Machines, 6(2), 24.
• Labidi, A., Tebassi, H., Belhadi, S., Khettabi, R., Yallese, M.A., 2018. Cutting Conditions Modeling and Optimization in Hard Turning Using RSM, ANN and Desirability Function. Journal of Failure Analysis and Prevention, 18(4), 1017-1033.
• Marczak, R.J., Ciach, R., 1973. Tribological Properties of the Concentrated Al-Zn Alloys, Proceedings of the 1st Europe Tribology Congress, London, UK.
• Martín-Béjar, S., Trujillo, F.J., Sevilla, L., Marcos, M., 2017. Indirect Adhesion Wear Parametric Analysis in the Dry Turning of UNS A97075 Alloys. Procedia Manufacturing, 13, 418-425.
• Meddour, I., Yallese, M.A., Khattabi, R., Elbah, M., Boulanouar, L., 2015. Investigation and Modeling of Cutting Forces and Surface Roughness When Hard Turning of AISI 52100 Steel with Mixed Ceramic Tool: Cutting Conditions Optimization. International Journal of Advanced Manufacturing Technology, 77(5-8), 1387-1399.
• Prasad, B.K., 2005. Sliding Wear Response of a Zinc-Based Alloy and its Composite and Comparison with a Gray Cast Iron: Influence of External Lubrication and Microstructural Features. Materials Science and Engineering A, 392(1-2), 427-439.
• Prasad, B.K., Patwardhan, A.K., Yagneswaran, A.H., 2001. Wear Characteristics of a Zinc-Based Alloy Compared with a Conventional Bearing Bronze under Mixed Lubrication Conditions: Effects of Material and Test Parameters. Canadian Metallurgical Quarterly, 40(2), 193-210.
• Sánchez, Y., Trujillo, F.J., Sevilla, L., Marcos, M., 2015. Study of the Influence of the Cutting Parameters on the Chip Geometry During Machining Alloy UNS A97075. Procedia Engineering, 132, 513-520.
• Savaşkan, T., Bican, O., Alemdağ, Y., 2009. Developing Aluminium-Zinc-Based a New Alloy for Tribological Applications. Journal of Materials Science, 44(8), 1969-1976.
• Savaşkan, T., Hekimoğlu, A.P., 2016. Relationships Between Mechanical and Tribological Properties of Zn-15Al-Based Ternary and Quaternary Alloys. International Journal of Materials Research, 107(7), 646-652.
• Suresh, R., Basavarajappa, S., Gaitonde, V.N., Samuel, G.L., 2012. Machinability Investigations on Hardened AISI 4340 Steel Using Coated Carbide Insert. International Journal of Refractory Metals and Hard Materials, 33, 75-86.
• Tosun, G., Muratoğlu, M., 2004. The Drilling of an Al/SiCp Metal-Matrix Composites, Part I: Microstructure. Composites Science Technology, 64(2), 299-308.
• Yi, J., Jiao, L., Wang, X., Xiang, J., Yuan, M., Gao, S., 2015. Surface Roughness Models and Their Experimental Validation in Micro Milling of 6061-T6 Al Alloy by Response Surface Methodology. Mathematical Problems in Engineering, 2015, 1-9.