Milling of Al 6060 Alloy with DLC Coated Cutting Tools

Year 2019, Volume: 3 Issue: 1, 25 - 29, 15.07.2019

Mustafa Ay , Ayhan Etyemez

Abstract

In this study, the effects of rotation, feed rate, and MQL cooling system flow on surface roughness and cutting forces in milling Al 6060 alloy with DLC coated cutting tools are investigated. Taguchi method was used in the test design. Thus, time and cost are saved in the tests. The results obtained from the tests were optimized and improved. Surface roughness and performance were improved with the Taguchi method. In this study, optimal workability of Al 6060 material with DLC coated end mill was tried to be determined with grey relational analysis and surface roughness and cutting force optimization was made. Ideal values were obtained when the revolution was 3500 rpm; the feed rate was 450 mm/min. Moreover, the MQL rate was 30 l/h.

Keywords

A1 6060, Cutting, GRA, MQL, Taguchi

Supporting Institution

BAPKO of Marmara University

Project Number

FEN-E090517-0273

References

• [1] Zhao T, Jiang Y. Fatigue of 7075-T651 Aluminum Alloy. International Journal of Fatigue (2008) 30:834–849.
• [2] Şeker U. Talaşlı İmalatta Takım Tasarımı, G.Ü. Fen Bilimleri Enstitüsü Yüksek Lisans Ders Notları [Tool Design in Machining G.Ü. Graduate School of Natural and Applied Sciences Course Notes]. Ankara (2000).
• [3] Deepak D, Rajendra B. Investigations on the surface roughness produced in turning of Al 6061 (as-cast) by Taguchi method. International Journal of Research in Engineering and Technology (2015) 4(8):295–298.
• [4] Pridhvijit A, Binu CY. Experimental Study and Parameter Optimization of Turning Operation of Aluminium Alloy2014. International Journal of Engineering Research and General Science (2015) 3(5):525–530.
• [5] Ranganath MS, Vipin, RS, Prateek M, Nikhil. Optimization of Surface Roughness in CNC Turning of Aluminium 6061 Using Taguchi Techniques. International Journal of Modern Engineering Research (IJMER) (2015) 5(5):42–50.
• [6] Rogov VA, Siamak G. Optimization of Surface Roughness and Vibration in Turning of Aluminum Alloy AA2024 Using Taguchi Technique. International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering (2013) 7(11):2330–2339.
• [7] List G, Nouari M, Géhin D, Gomez S, Manaud JP, Le Petitcorps Y, et al. Wear behavior of cemented carbide tools in dry machining of aluminium alloy. Wear (2015) 259(7-12):1177–1189.
• [8] Settineri L, Bucciotti F. Cesano F, Faga MG. Surface Properties of Diamond Coatings for Cutting Tools. CIRP Annals (2007) 56:573–576.
• [9] Trava-Airoldi VJ, Bonetti LF, Capote G, Santos LV, Corat EJ. A comparison of DLC film properties obtained by r.f. PACVD, IBAD, and enhanced pulsed-DC PACVD. Surface and Coatings Technology (2007) 202:549–554.
• [10] Liu Y, Meletis E, Erdemir A. A study on wear mechanism of diamond-like carbon films. Surface and Coatings Technology (1996) 82:48–56.
• [11] Vandevelde TCS, Vandierendonck K, van Stappen M, Du Mong W, Perremans P. Cutting applications of DLC, hard carbon and diamond films. Surface and Coatings Technology (1999) 113:80–85.
• [12] Chandra SY, Gopichand A, Sam SR, Pavan KN. Optimization of Surface Roughness of 6463 Aluminium Alloy and Brass Materials in CNC Milling Operation Using Taguchi’s Design. International Journal of Innovative Research in Science, Engineering and Technology (2017) 6(2):1553-1560.
• [13] Uenga HY, Guob CT, Dittrich K. Development of a hybrid coating process for deposition of diamond-like carbon films on microdrills. Surface and Coatings Technology (2007) 200:2900–2908.
• [14] Etyemez A. Optimization of Effects of Pocket Tool Path Strategies and Cutting Parameters on Surface Quality. Acta Physica Polonica, A (2016) 129(4):886–889.
• [15] Ay M, Etyemez A. Optimization of Effects of Cutting Parameters and Cutting Tool Path by using Grey Based Taguchi Method. Acta Physica Polonica, A (2018) 134(1):125–128.
• [16] Saravanakumar A, Sasikumar P, Nilavusri N. Optimization of Machining Parameters using the Taguchi Method for Surface Roughness. Journal of Materials and Environmental Science (2016) 7(5):1556–1561.
• [17] Satish Kumar MD, Prasad J, Abhishek Krishna D, Venkat Narayana M, Anusha M, Saravanakumar A. Parametric optimization of aluminium alloy milling using Taguchi method for surface roughness. International Journal of Scientific Research and Review (2018) 7(3):517-522.
• [18] Sakthivelu S, Anandaraj T, Selwin M. Multi-Objective Optimization of Machining Conditions on Surface Roughness and MRR during CNC End Milling of Aluminium Alloy 7075 Using Taguchi Design of Experiments. Mechanics and Mechanical Engineering (2017) 21(1):95-103.
• [19] Basmacı G, Ay M, Etyemez A. The Grey-Based Taguchi Method: Optimization of Milling of Mold Steel. Acta Physica Polonica, A (2018) 134(1):24–27.
• [20] Basmacı G, Ay M, Kırbaş İ. Optimisation of Machining Parameters in Turning 17-4 Ph Stainless Steel Using the Grey-Based Taguchi Method. Erzincan University Journal of Science and Technology (2017) 10(2):243–254.
• [21] Ay M. Optimisation of Machining Parameters in Turning AISI 304L Stainless Steel by the Grey-Based Taguchi Method. Acta Physica Polonica, A (2017) 131(3):349–353.