Waspaloy süper alaşımının farklı soğutma teknikleri kullanarak frezeleme yöntemi ile işlenebilirliğinin incelenmesi
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Dosyalar
Tarih
2017
Yazarlar
Dergi Başlığı
Dergi ISSN
Cilt Başlığı
Yayıncı
Düzce Üniversitesi
Erişim Hakkı
info:eu-repo/semantics/openAccess
Özet
Bu çalışmada, nikel esaslı Waspaloy süper alaşımının frezelenmesinde kesme parametrelerinin ve soğutma-yağlama tekniklerinin işlenebilirlik üzerindeki etkileri irdelenmiştir. İlk etapta kesme hızı, ilerleme, kesme derinliği ve kesici takım sabit tutularak yağ tipi, debi, frezeleme yönü, püskürtme mesafesi ve nozul tipinin giriş parametresi seçildiği 16 deney gerçekleştirilmiştir. Bu deneyler sonucunda bitkisel yağ, 100 ml/s debi, zıt yönlü frezeleme, 25 mm püskürtme mesafesi ve 1 nolu nozul ile ana deneylerde kullanılacak minimum miktarda yağlama parametreleri belirlenmiştir. Ana deneyler için birinci grup kesici takım malzemesi olarak kaplamasız, PVD-TiAlN ve CVD - TiCN+Al2O3+TiN kaplamalı karbür seçilmiştir. Kesme parametresi; kesme hızı (30, 45, 60 m/dak), ilerleme (0.10, 0.15, 0.20 mm/dev) ve soğutma-yağlama yöntemi seçilmiştir. İkinci grup kesici takım malzemesi olarak alümina, whiskers ve sialon esaslı seramik uçlar belirlenmiştir. Kesme parametresi; kesme hızı (500, 600, 700 m/dak), ilerleme (0.02, 0.04, 0.06 mm/dev) ve soğutma-yağlama yöntemi seçilmiştir. Deneyler sonucunda elde edilen değerler için varyans analizi (ANOVA) yapılarak işleme parametrelerinin kesme kuvveti, yüzey pürüzlülüğü ve takım ömrü/aşınması üzerindeki etkisi incelenmiştir. Çalışmanın sonucunda regresyon analizi aracılığı ile tahmin denklemleri oluşturularak gelecekte yapılması düşünülen benzer çalışmalar için tahmin modelleri elde edilmiştir. Sonuç olarak; karbür kesiciler için en yüksek takım ömrü ıslak işleme, PVD (TiAlN) kaplamalı karbür, 30 m/dak kesme hızı ve 0.1 mm/dev ilerleme ile çıkmıştır. En düşük kesme kuvveti değerini ıslak işleme, PVD (TiAlN) kaplamalı uç, 45 m/dak kesme hızı ve 0.1 mm/dev ilerleme vermiştir. En düşük yüzey pürüzlülüğü değerini ıslak işleme, PVD (TiAlN) kaplamalı uç, 45 m/dak kesme hızı ve 0.1 mm/dev ilerleme vermiştir. Seramik takımlar için en düşük aşınma değeri minimum miktarda yağlama (MMY), sialon uç, 700 m/dak kesme hızı ve 0.06 mm/dev ilerleme şartlarında gerçekleşmiştir. En düşük kesme kuvveti değerini MMY, sialon uç, 600 m/dak kesme hızı ve 0.02 mm/dev ilerleme şartları vermiştir. En düşük yüzey pürüzlülüğü değerini ise MMY, sialon uç, 700 m/dak kesme hızı ve 0.02 mm/dev ilerleme şartları vermiştir.
In this study, the effects of the cutting parameters and the cooling methods on the machinability in the milling of nickel based Waspaloy were investigated. In the first step, 16 experiments were carried out the input parameters of oil type, flow rate, milling direction, spray distance and nozzle type were selected while keeping the cutting speed, feed, depth of cut and cutting tool constant. As a result of these experiments, the minimum quantity of lubrication parameters which use for the main experiments with vegetable oil, 100 ml/h flow rate, up milling, 25 mm spray distance and 1 nozzle were determined. For the main experiments, Uncoated, PVD (TiAlN) and CVD (TiCN+Al2O3+TiN) coated carbide was selected as the first group cutting tool materials. As the cutting parameters; cutting speed (30, 45, 60 m/min), feed rate (0.10, 0.15, 0.20 mm/rev) and cooling method were selected. Alumina, whiskers and sialon based ceramic insert were determined as the second group of cutting tools. As a cutting parameter; cutting speed (500, 600, 700 m/min), feed rate (0.02, 0.04, 0.06 mm/rev) and cooling method were selected. The effects of cutting parameters on cutting force, surface roughness and tool life/wear were investigated by Variance analysis (ANOVA) was performed for values which obtained as a result of the experiments. As a result of the study, prediction equations are created through regression analysis and prediction models are obtained for similar studies that are thought to be done in the future. As a result; the highest tool life for carbide inserts was achieved with wet machining, PVD (TiAlN) coated carbide, 30 m/min cutting speed and 0.1 mm/rev feed rate. The lowest cutting force value was obtained by wet machining, PVD (TiAlN) coated tip, 45 m/min cutting speed and 0.1 mm/rev feed rate. The lowest surface roughness value was obtained by wet machining, PVD (TiAlN) coated carbide, 45 m/min cutting speed and 0.1 mm/rev feed rate. The lowest wear value for ceramic tools was obtained with Minimum Quantity Lubrication (MQL), sialon insert, 700 m/min cutting speed and 0.06 mm/rev feed rate. The lowest cutting force value obtained with MQL, sialon insert, cutting speed of 600 m/min and 0.02 mm/rev feed rate. The lowest surface roughness value was given with MQL, sialon insert, cutting speed of 700 m/min and 0.02 mm/rev feed rate parameters.
In this study, the effects of the cutting parameters and the cooling methods on the machinability in the milling of nickel based Waspaloy were investigated. In the first step, 16 experiments were carried out the input parameters of oil type, flow rate, milling direction, spray distance and nozzle type were selected while keeping the cutting speed, feed, depth of cut and cutting tool constant. As a result of these experiments, the minimum quantity of lubrication parameters which use for the main experiments with vegetable oil, 100 ml/h flow rate, up milling, 25 mm spray distance and 1 nozzle were determined. For the main experiments, Uncoated, PVD (TiAlN) and CVD (TiCN+Al2O3+TiN) coated carbide was selected as the first group cutting tool materials. As the cutting parameters; cutting speed (30, 45, 60 m/min), feed rate (0.10, 0.15, 0.20 mm/rev) and cooling method were selected. Alumina, whiskers and sialon based ceramic insert were determined as the second group of cutting tools. As a cutting parameter; cutting speed (500, 600, 700 m/min), feed rate (0.02, 0.04, 0.06 mm/rev) and cooling method were selected. The effects of cutting parameters on cutting force, surface roughness and tool life/wear were investigated by Variance analysis (ANOVA) was performed for values which obtained as a result of the experiments. As a result of the study, prediction equations are created through regression analysis and prediction models are obtained for similar studies that are thought to be done in the future. As a result; the highest tool life for carbide inserts was achieved with wet machining, PVD (TiAlN) coated carbide, 30 m/min cutting speed and 0.1 mm/rev feed rate. The lowest cutting force value was obtained by wet machining, PVD (TiAlN) coated tip, 45 m/min cutting speed and 0.1 mm/rev feed rate. The lowest surface roughness value was obtained by wet machining, PVD (TiAlN) coated carbide, 45 m/min cutting speed and 0.1 mm/rev feed rate. The lowest wear value for ceramic tools was obtained with Minimum Quantity Lubrication (MQL), sialon insert, 700 m/min cutting speed and 0.06 mm/rev feed rate. The lowest cutting force value obtained with MQL, sialon insert, cutting speed of 600 m/min and 0.02 mm/rev feed rate. The lowest surface roughness value was given with MQL, sialon insert, cutting speed of 700 m/min and 0.02 mm/rev feed rate parameters.
Açıklama
YÖK Tez No: 473066
Anahtar Kelimeler
Makine Mühendisliği, Mechanical Engineering, CNC frezeleme, CNC milling
