Study on Consumed Energy of Strenx 1100 Steel During MQL Assisted Hard Milling

Öz

Strenx 1100 is a structural steel utilized in the critical engineering applications such as marine, crane and transportation thanks to its high tensile and yield strength properties. Despite its advantages coming from mechanical properties, hard-to-cut structure of this material makes difficult the metal removing. Therefore, high amount of energy consumption reveals due to the requirement of high cutting forces. In order to overcome this problem, recently, minimum quantity lubrication (MQL) supported machining have been introduced from many authors. In this context, this study aims to measure and analyze the consumed energy in MQL assisted surface milling of Strenx 1100 steel. For this purpose, experimental results were evaluated by three methods: analysis on graphs, ANOVA based statistical evaluation and signal to noise (S/N) ratio based optimization. In the experiments, with the help of Taguchi, L9 orthogonal array design was adopted using three levels of cutting speed, feed rate and depth of cut. According to the obtained findings, cutting speed is the most effective parameter according to contribution rate (46.28%) and P value (0.048<0.05), meanwhile feed rate (23.6%) and depth of cut (27.8%) have important contributors on the consumed energy during milling. Seemingly, general trend for the consumed energy is about to increase with higher values of cutting speed and depth of cut and lower values of feed rate according to 3D plots. This situation is confirmed with optimal solutions as vC=75 m/min, f=0.25 mm, aP=0.225 mm/rev achieved by S/N ratios. Conducted experiments and further analysis provide an important guidance for the industrial applications in MQL reinforced machining of hard materials.

Anahtar Kelimeler

• Strenx 1100
• Energy
• MQL
• Hard Milling

Strenx 1100 Çeliğinin MMY Yardımıyla Sert Frezelenmesinde Enerji Tüketimi Üzerine Çalışma

Öz

Strenx 1100, yüksek çekme ve akma dayanımı özellikleri sayesinde denizcilik, vinç ve nakliye gibi kritik mühendislik uygulamalarında kullanılan bir yapısal çeliktir. Mekanik özelliklerinden gelen avantajlarına rağmen, yine bu özellikler malzemeden talaş kaldırmayı güçleştirmektedir. Bu sebeple yüksek kesme kuvvetlerine ihtiyaç duyulması nedeniyle yüksek miktarda enerji tüketimi ortaya çıkar. Bu sorunun üstesinden gelmek için, son zamanlarda, birçok yazar minimum miktarda yağlama (MMY) destekli işleme öne sürülmüştür. Bu bağlamda, bu çalışma Strenx 1100 çeliğinin MMY destekli yüzey frezelemesinde tüketilen enerjiyi ölçerek analiz etmeyi amaçlamaktadır. Bu amaçla elde edilen deneysel sonuçlar 3 şekilde değerlendirilmiştir: grafikler üzerinden analiz, ANOVA tabanlı istatistiksel değerlendirme ve sinyal / gürültü (S / N) oranına dayalı optimizasyon. Deneylerde, Taguchi yardımıyla L9 ortogonal dizi tasarımı, üç seviyede kesme hızı, ilerleme ve talaş derinliği kullanılarak uygulanmıştır. Elde edilen bulgulara göre kesme hızı, katkı oranı (% 46.28) ve P değerine (0.048 <0.05) göre enerji tüketiminde en etkili parametredir, bu arada ilerleme hızı (% 23.6) ve kesme derinliğinin (% 27.8) tüketilen enerji üzerinde önemli katkıları vardır. Görünüşe göre, 3D grafikler incelendiğinde, tüketilen enerji için genel eğilimin, daha yüksek kesme hızı ve talaş derinliği değerleri ve daha düşük ilerleme değerleri için arttığı gözlenmiştir. Bu durum, S / N oranlarıyla elde edilen vC=75 m/dak, f=0.25 mm, aP=0.225 mm/dev optimal çözümlerle doğrulanmıştır. Gerçekleştirilen deneyler ve daha ileri analizler, sert malzemelerin MMY ile destekli işlemesinde endüstriyel uygulamalar için önemli bir rehberlik sağlar.

Anahtar Kelimeler

• Strenx 1100
• Enerji
• MMY
• Sert frezeleme

Kaynakça

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