Talaş Kaldırma İşleminde Sürtünme Katsayısının Kesme Kuvvetleri, Sıcaklık ve Kesici Takım Gerilmeleri Üzerine Etkisi
Abstract
Bu çalışmada, endüstride büyük önem taşıyan tornalama işleminde kullanılan kesici takımların kesme performansının iyileştirilmesi amaçlanmıştır. Karbür kesici takımlarla AISI 1050 çeliği üzerinde farklı kesme parametreleriyle deneyler yapılmış ve dinamometre yardımıyla kesme kuvvetleri ölçülmüştür. Kesme parametreleri referans alınarak Deform-3D ile simülasyonlar yapılmıştır. Farklı sürtünme katsayılarıyla (0.3-0.4-0.5-0.6-0.7) yapılan simülasyonlardan elde edilen kesme kuvvetleri ile deneysel sonuçlar karşılaştırılmıştır. Ayrıca sürtünme katsayısının sıcaklık ve kesici takım gerilmeleri üzerindeki etkileri incelenmiştir. 0.4 ve 0.5 sürtünme katsayıları için simülasyon ve deneysel kesme kuvveti sonuçlarının birbirine yakın olduğu görülmüştür. Analizler sonucunda sürtünmenin kesici takım gerilmeleri ve sıcaklık üzerinde çok etkili olduğu gözlenmiştir. Sıcaklığa ve gerilmelere bağlı olarak kesici takımda oluşabilecek aşınma ve hasar noktaları belirlenmiştir. Çalışmadan elde edilen sonuçlar, kesici takım kesme performansının iyileştirilmesine ve optimum kesme parametrelerinin seçiminde önemli katkılar sağlayacaktır.
Keywords
Kesme kuvvetleri kesici takım gerilmeleri sürtünme katsayısı sonlu elemanlar takım-talaş ara yüzeyi
Project Number
Gazi Üniversitesi Bilimsel Araştırma Projeleri Birimi (Proje Kodu: 07/2010-56)
Thanks
Bu çalışmanın tamamlanmasında sağladığı mali destekten dolayı Gazi Üniversitesi Bilimsel Araştırma Projeleri Birimi’ne (Proje Kodu: 07/2010-56) ve simülasyon çalışmalarının yapılmasında DEFORM yazılımını araştırma amaçlı olarak lisanslı kullanım imkanı sağlamalarından dolayı da DEFORM yazılımının Türkiye distribütörü olan FİGES’e teşekkür ederim.
References
- Aslan D, Budak E, 2014. Semi analytical force model for grinding operations. 6th CIRP International Conference on High Performance Cutting, Procedia CIRP, 14: 7-12.
- Attanasio A, Ceretti E, Rizzuti S, Umbrello D, Micari F, 2008. 3D finite element analysis of tool wear in machining. CIRP Annals -Manufacturing Technology, 57: 61-64.
- Attanasio A, Faini F, Outeiro JC, 2017. FEM simulation of tool wear in drilling. Procedia Cirp, 58: 440-444.
- Binder M, Klocke F, Doebbeler B, 2017. An advanced numerical approach on tool wear simulation for tool and process design in metal cutting. Simulation Modelling Practice and Theory, 70: 65-82.
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- Ezilarasan C, Velayudham A, 2017. Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy. Simulation Modelling Practice and Theory, 40: 192-207.
- Gök K., 2015. Development of three-dimensional finite element model to calculate the turning processing parameters in turning operations. Measurement, 75: 57-68.
- Gökçe H, Biberci M. A, 2022. Investigation of thrust force, drill bit temperature and burr height in the drilling of aluminum alloy used in ammunition wing drive systems. Experimental Techniques, 46(4), 691-705.
- Kendall LA, 1995. Friction and Wear of Cutting Tools and Cutting Tool Material. ASM Metal Handbook, Friction, Lubrication and Wear vol. 18, ASM International, Ohio.
- Kherraf A, Tamerabet Y, Brioua M, Benbouta R, 2019. Chip formation process using finite element simulation “influence of cutting speed variation” J. Solid Mech. 4: pp. 854-861.
- Küçüktürk G, 2013. Modeling and analyzing the effects of experimentally determined torque and thrust force on cutting tool according to drilling parameters. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 227: 84-95.
- Kurt A, 2009. Modelling of the cutting tool stresses in machining of Inconel 718 using artificial neural networks. Expert Systems with Applications, 36 (6): 9645-9657.
- Kurt, A, 2006 . Talaş Kaldırma Sırasında Oluşan Kesme Kuvvetleri ve Mekanik Gerilmelerin Deneysel Olarak İncelenmesi ve Matematiksel Modellerin Oluşturulması. Doktora Tezi, Gazi Üniversitesi Fen Bilimleri Enstitüsü, Ankara, 4: 25-30, 44-53, 108-112.
- Maranhao C, Davim J P, 2012. The role of flow stress and friction coefficient in fem analysis of machining. Rev. Adv . Mater. Sci., 30: 184-188.
- Özbek O, Saruhan H, 2020. The effect of vibration and cutting zone temperature on surface roughness and tool wear in eco-friendly MQL turning of AISI D2. Journal of Materials Research and Technology, 9(3), 2762-2772.
- Özel T, 2009. Computational modelling of 3D turning: Influence of edge micro-geometry on forces, stresses, friction and tool wear in PcBN tooling. J. Mater. Pro. Techno, 209 (11): 5167-5177.
- Sekmen M, Günay M, Şeker U, 2015. Alüminyum alaşımlarının işlenmesinde kesme hızı ve talaş açısının yüzey pürüzlülüğü, yığıntı talaş ve yığıntı katmanı oluşumu üzerine etkisi. Politeknik dergisi, 18(3): 141-148.
- Soldani X, Moufki A, Molinari A, Budak E, Özlü E, 2008. High speed machining of AISI 1050 Steel: modelling and experimental. Int. J. Mater. Form., 1: 1439-1441.
- Tang SH, Kong YM, Sapuan SM, Samin R, Sulaiman S, 2006. Design and thermal analysis of plastic injection mould. J. Mater. Pro. Techno, 171(2): 259-267.
- Ucun İ, Aslantas K, 2011. Numerical simulation of orthogonal machining process using multilayer and single-layer coated tools. Int J Adv Manuf Technol, 54: 899-910.
- Ucun İ, Aslantaş K, Apaydın D, 2010. Çok Kaplamalı Kesici Takımla Tornalama İşleminin Sonlu Elemanlar Yöntemiyle Modellenmesi. Electronic Journal of Machine Technologies, 7(1): 69-82.
- Xiong Y, Wang W, Jiang R, Lin K, Shao M, 2018. Mechanisms and FEM simulation of chip formation in orthogonal cutting in-situ TiB2/7050Al MMC. Materials, 11(4); 606.
- Yanda H, Ghani JA, Hassan C, 2009. Effect of rake and clearance angles on the wear of carbide cuttig tool. Department of Mechanical and Materials Engineering, 4: 7-13.
- Yıldız A, Kurt A, Yağmur S, 2020. Finite element simulation of drilling operation and theoretical analysis of drill stresses with the deform-3D. Simulation Modelling Practice and Theory, 104: 102153.
The Effect of Friction Coefficient on Cutting Forces, Temperature and Cutting Tool Stresses in Machining Process
Abstract
In this study, it is aimed to improve the cutting performance of the cutting tools used in the turning process, which is of great importance in the industry. Experiments with different cutting parameters were carried out on AISI 1050 steel with carbide cutting tools and cutting forces were measured with the help of a dynamometer. Simulations were made with Deform-3D by taking the cutting parameters as reference. The experimental results and the cutting forces obtained from the simulations carried out with different friction coefficients (0.3-0.4-0.5-0.6-0.7) were compared. In addition, the effects of friction coefficient on temperature and cutting tool stresses were investigated. It has been seen that the simulation and experimental cutting force results for friction coefficients of 0.4 and 0.5 are close to each other. As a result of the analyses, it has been observed that friction has a great effect on cutting tool stresses and temperature. Depending on the temperature and stresses, the wear and damage points that may occur in the cutting tool have been determined. The results obtained from the study will make significant contributions to the improvement of cutting tool cutting performance and the selection of optimal cutting parameters.
Keywords
Cutting forces cutting tool stresses friction coefficient finite elements tool-chip interface
Project Number
Gazi Üniversitesi Bilimsel Araştırma Projeleri Birimi (Proje Kodu: 07/2010-56)
References
- Aslan D, Budak E, 2014. Semi analytical force model for grinding operations. 6th CIRP International Conference on High Performance Cutting, Procedia CIRP, 14: 7-12.
- Attanasio A, Ceretti E, Rizzuti S, Umbrello D, Micari F, 2008. 3D finite element analysis of tool wear in machining. CIRP Annals -Manufacturing Technology, 57: 61-64.
- Attanasio A, Faini F, Outeiro JC, 2017. FEM simulation of tool wear in drilling. Procedia Cirp, 58: 440-444.
- Binder M, Klocke F, Doebbeler B, 2017. An advanced numerical approach on tool wear simulation for tool and process design in metal cutting. Simulation Modelling Practice and Theory, 70: 65-82.
- Borsos B, Csörgö A, Hidas A, Kotnyek B, Szabo A, Kossa A, Stepan G, 2017. Two-Dimensional Finite Element Analysis of Turning Processes Periodica Polytech. Mech. Eng., 61: 44-54.
- Budak E, Ozlu E, 2008. Development of a thermomechanical cutting process model for machining process simulations. CIRP Annals-Manufacturing Technology, 57 (1): 97-100.
- Ezilarasan C, Velayudham A, 2017. Theoretical predictions and experimental validations on machining the Nimonic C-263 super alloy. Simulation Modelling Practice and Theory, 40: 192-207.
- Gök K., 2015. Development of three-dimensional finite element model to calculate the turning processing parameters in turning operations. Measurement, 75: 57-68.
- Gökçe H, Biberci M. A, 2022. Investigation of thrust force, drill bit temperature and burr height in the drilling of aluminum alloy used in ammunition wing drive systems. Experimental Techniques, 46(4), 691-705.
- Kendall LA, 1995. Friction and Wear of Cutting Tools and Cutting Tool Material. ASM Metal Handbook, Friction, Lubrication and Wear vol. 18, ASM International, Ohio.
- Kherraf A, Tamerabet Y, Brioua M, Benbouta R, 2019. Chip formation process using finite element simulation “influence of cutting speed variation” J. Solid Mech. 4: pp. 854-861.
- Küçüktürk G, 2013. Modeling and analyzing the effects of experimentally determined torque and thrust force on cutting tool according to drilling parameters. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 227: 84-95.
- Kurt A, 2009. Modelling of the cutting tool stresses in machining of Inconel 718 using artificial neural networks. Expert Systems with Applications, 36 (6): 9645-9657.
- Kurt, A, 2006 . Talaş Kaldırma Sırasında Oluşan Kesme Kuvvetleri ve Mekanik Gerilmelerin Deneysel Olarak İncelenmesi ve Matematiksel Modellerin Oluşturulması. Doktora Tezi, Gazi Üniversitesi Fen Bilimleri Enstitüsü, Ankara, 4: 25-30, 44-53, 108-112.
- Maranhao C, Davim J P, 2012. The role of flow stress and friction coefficient in fem analysis of machining. Rev. Adv . Mater. Sci., 30: 184-188.
- Özbek O, Saruhan H, 2020. The effect of vibration and cutting zone temperature on surface roughness and tool wear in eco-friendly MQL turning of AISI D2. Journal of Materials Research and Technology, 9(3), 2762-2772.
- Özel T, 2009. Computational modelling of 3D turning: Influence of edge micro-geometry on forces, stresses, friction and tool wear in PcBN tooling. J. Mater. Pro. Techno, 209 (11): 5167-5177.
- Sekmen M, Günay M, Şeker U, 2015. Alüminyum alaşımlarının işlenmesinde kesme hızı ve talaş açısının yüzey pürüzlülüğü, yığıntı talaş ve yığıntı katmanı oluşumu üzerine etkisi. Politeknik dergisi, 18(3): 141-148.
- Soldani X, Moufki A, Molinari A, Budak E, Özlü E, 2008. High speed machining of AISI 1050 Steel: modelling and experimental. Int. J. Mater. Form., 1: 1439-1441.
- Tang SH, Kong YM, Sapuan SM, Samin R, Sulaiman S, 2006. Design and thermal analysis of plastic injection mould. J. Mater. Pro. Techno, 171(2): 259-267.
- Ucun İ, Aslantas K, 2011. Numerical simulation of orthogonal machining process using multilayer and single-layer coated tools. Int J Adv Manuf Technol, 54: 899-910.
- Ucun İ, Aslantaş K, Apaydın D, 2010. Çok Kaplamalı Kesici Takımla Tornalama İşleminin Sonlu Elemanlar Yöntemiyle Modellenmesi. Electronic Journal of Machine Technologies, 7(1): 69-82.
- Xiong Y, Wang W, Jiang R, Lin K, Shao M, 2018. Mechanisms and FEM simulation of chip formation in orthogonal cutting in-situ TiB2/7050Al MMC. Materials, 11(4); 606.
- Yanda H, Ghani JA, Hassan C, 2009. Effect of rake and clearance angles on the wear of carbide cuttig tool. Department of Mechanical and Materials Engineering, 4: 7-13.
- Yıldız A, Kurt A, Yağmur S, 2020. Finite element simulation of drilling operation and theoretical analysis of drill stresses with the deform-3D. Simulation Modelling Practice and Theory, 104: 102153.
Details
| Primary Language | Turkish |
|---|---|
| Subjects | Mechanical Engineering |
| Journal Section | Makina Mühendisliği / Mechanical Engineering |
| Authors | |
| Project Number | Gazi Üniversitesi Bilimsel Araştırma Projeleri Birimi (Proje Kodu: 07/2010-56) |
| Early Pub Date | May 27, 2023 |
| Publication Date | June 1, 2023 |
| Submission Date | November 22, 2022 |
| Acceptance Date | February 2, 2023 |
| Published in Issue | Year 2023 Volume: 13 Issue: 2 |
