Optimization of Cutting Parameters for Surface Roughness in Milling of Cryogenic Treated EN AW 5754 (AlMg3) Aluminum Alloy

Öz

Aluminum alloys are now widely used in plastic injection molds in the automotive and aerospace industries due to their high strength and weight ratio, good corrosion and fatigue resistance. In this study, EN AW 5754 (AlMg₃) 5754 aluminum alloy with dimensions of 80x80x30 mm was subjected to cryogenic treatment, face milling was performed with coated and uncoated inserts, and then the effects of cutting parameters on surface roughness during face milling were examined. The experiments were conducted with Taguchi L₉ orthogonal array, using three different cutting inserts (Al₂O₃-TiCN-TiN coated, TiAlN coated Nano, TiB₂ coated), cutting speeds (310, 450, 600 m / min), feed rates (0.15, 0.25, 0.35 mm / tooth) and depths of cut (0.5, 1, 1.5 mm). The values obtained at the end of the experiments were evaluated using signal-to-noise ratio (S/N), variance analysis (ANOVA), three-dimensional graphs and regression method. Taguchi analysis has revealed that optimum cutting conditions for the minimum surface roughness are the Al₂O₃-TiCN-TiN coated insert, 1 mm depth of cut, 600 m/min cutting speed and 0.15 mm/tooth feed rate. The surface roughness values for these cutting conditions were found as 0.47 μm in the calculations and 0.32 μm in the verification experiments.

Anahtar Kelimeler

• EN AW 5754,surface roughness,cryogenic process,Taguchi method

Kriyojenik İşlem Görmüş EN AW 5754 (AlMg3) Alüminyum Alaşımının Frezelenmesinde Yüzey Pürüzlülüğü İçin Kesme Parametrelerinin Optimizasyonu

Öz

Alüminyum alaşımları günümüzde, yüksek dayanım ve ağırlık oranı, iyi korozyon ve yorulma direnci nedeniyle, otomotiv ve havacılık sanayinde, plastik enjeksiyon kalıplarında yaygın bir şekilde kullanılmaktadır. Bu çalışmada, 80x80x30 mm ebatlarında EN AW 5754 (AlMg₃)  alüminyum alaşımına kriyojenik işlem uygulanmış, kaplamalı ve kaplamasız kesici uçlarla yüzey frezeleme işlemi gerçekleştirilmiş ve yüzey frezeleme işlemi esnasında kesme parametrelerinin yüzey pürüzlülüğü üzerindeki etkileri araştırılmıştır. Deneylerde Taguchi L₉ ortogonal dizini ile üç farklı kesici uç (Al₂O₃-TiCN-TiN kaplamalı, TiAlN kaplamalı Nano, TiB₂ kaplamalı), kesme hızı (310, 450, 600 m/dak), ilerleme oranı (0.15, 0.25, 0.35 mm/diş) ve üç farklı kesme derinliği (0.5, 1, 1.5 mm) kullanılmıştır. Deneyler sonucunda elde edilen değerler, sinyal-gürültü oranı (S/N), varyans analizi (ANOVA), üç boyutlu grafikler ve regresyon metodu kullanılarak değerlendirilmiştir. Taguchi analizi sonucu minimum yüzey pürüzlülüğü için elde edilen optimum kesme şartları; Al₂O₃-TiCN-TiN kaplamalı kesici uç, 1 mm kesme derinliği, 600 m/dak kesme hızı ve 0.15 mm/diş ilerleme oranı olarak bulunmuştur. Bu kesme şartları için yüzey pürüzlülük değerleri hesaplamalarda 0.47 µm olarak bulunmuş, doğrulama deneylerinde 0.32 µm olarak ölçülmüştür.

Anahtar Kelimeler

• yüzey pürüzlülüğü,kriyojenik işlem,Taguchi metodu,EN AW 5754

Kaynakça

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