Talaşlı imalatta nano-akışkan kullanımının soğutmaya etkilerinin deneysel olarak araştırılması

Öz

Nano-akışkanların talaşlı imalat süreçlerinde kullanımı, gelişmiş termo-fiziksel özellikleri sayesinde giderek daha yaygın hale gelmektedir. Önceki çalışmalar; Al2O3, MWCNT veya TiO2 gibi nano-parçacıkların, temel akışkanlara eklenmesinin yoğunluk, viskozite ve ısıl iletkenlik gibi özelikleri iyileştirdiğini göstermektedir. Bu deneysel çalışma; söz konusu nano-parçacıkların %0.5, %1 ve %1.5 oranlarında bor yağı–su karışımına eklenmesinin etkisini incelemektedir. Araştırma üç ana aşamada gerçekleştirilmiştir: Nano-akışkan hazırlanması, termo-fiziksel özeliklerin değerlendirilmesi ve Ti-6Al-4V alaşımı kullanılarak yapılan talaşlı imalat deneyleri. Sonuçlar, 24.5 °C’da nano-parçacık derişikliğinin artmasının akışkan yoğunluğunda sürekli bir artışa yol açtığını ortaya koymuştur. Ancak, dinamik viskozite ve ısıl iletkenlik için benzer bir artış gözlemlenmemiş; bu özelikler, %1’in üzerindeki derişikliklerde azalmaya başlamıştır. Bu azalma, çökelme ve tortulaşma gibi akışkan kararsızlığı problemlerine bağlanmıştır. Ayrıca; nano-akışkan kullanımı, takım–iş parçası ara-yüzeyindeki sıcaklığı önemli ölçüde düşürmüştür. Örneğin, %0.5 oranında MWCNT parçacığı kullanımı bu sıcaklığı yaklaşık %18 oranında azaltmıştır. Diğer taraftan; daha yüksek derişiklikler, parçacık birikimi nedeniyle ara-yüzey sıcaklığında artışa ve yüzey pürüzlülüğünde kötüleşmeye neden olmuştur. Özellikle %0.5 MWCNT kullanımı, yüzey kalitesinde yaklaşık %25’lik bir iyileşme sağlamıştır. Bu çalışma; talaşlı imalat performansının yalnızca optimum nano-parçacık derişikliklerinde iyileştirilebildiğini; aşırı miktarda nano-parçacık kullanımının performansı düşürdüğünü ve bu bulgunun kesici uçların SEM analizleriyle desteklendiğini ortaya koymuştur.

Anahtar Kelimeler

• Bor mineral yağı-su karışımı
• Nano-akışkan
• Termofiziksel özelik
• Yüzey pürüzlülüğü
• Talaşlı imalat

Experimental investigation of effects of nano-fluid usage on cooling in machining

Öz

Application of nano-fluids in machining processes is becoming increasingly common due to their enhanced thermo-physical characteristics. Previous studies indicate that adding nano-particles such as Al2O3, MWCNT, or TiO2 into base fluids improves properties like density, viscosity, and thermal conductivity. This experimental study investigates the impact of addition of these nano-particles at concentrations of 0.5%, 1%, and 1.5% into a boron oil–water mixture. The research was carried out in three main phases: Nano-fluid preparation, thermo-physical property evaluation, and machining experiments on Ti-6Al-4V alloy. The results showed that increasing the nano-particle concentration led to a consistent rise in fluid density at 24.5 °C. However, similar trends were not observed for dynamic viscosity and thermal conductivity, which began to decline beyond 1% concentration of nano-particles. This decrease was attributed to fluid instability issues like precipitation and sedimentation. Furthermore, the use of nano-fluids significantly marked down temperature at the tool–workpiece interface. For instance, a 0.5% concentration of MWCNT particles reduced this temperature by approximately 18%. On the other hand, higher concentrations resulted in increased interface temperatures and worsened surface roughness due to particle deposition. Specifically, the use of 0.5% MWCNT improved surface finish by around 25%. The study concluded that machining performance benefits from nano-fluids only when used at optimal concentrations, as excessive amounts of nano-particles degrades performance-a finding supported by SEM analyses of the cutting inserts.

Anahtar Kelimeler

• Boron mineral oil–water mixture
• Nano-fluid
• Thermo-physical property
• Surface roughness
• Machining

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