Investigation of the Effects of DLC Cutting Tool and Machining Parameters on Surface Quality and Cutting Force

Yıl 2019, Sayı: 16, 494 - 504, 31.08.2019

Ayhan Etyemez

https://doi.org/10.31590/ejosat.573269

Öz

In this study, the surface roughness and cutting forces of Al 7075 alloy were investigated experimentally while milling with cutting tool coated by Diamond-Like-Carbon (DLC). The influence of feed, cutting speed and depth of cut on surface roughness and cutting forces was analysed. Taguchi technique was used when designing the experiment. With this way, the time and cost of the experiments economised, and the data found from the experimental outcomes were adjusted, and improvement was performed. The connection between the dependent and independent variables was modelled mathematically by regression analysis method. As a result, the most effective factor in the formation of surface roughness with ANOVA was the feed with 92.46%, the most effective factor in the creation of cutting force was the depth of cut with 82.91 %. With the regression analysis, Ra's predictive equation was obtained with an accuracy of 94.7%, and the force estimation of the equation with 87.1% accuracy. In this study where the Taguchi method has been applied, the processing methods such as cutting force and surface roughness have been minimized, the performance has been increased, and the product quality has been improved.

Anahtar Kelimeler

DLC coated tools, Aluminium 7075, Taguchi, Regression Analysis, Variance Analysis (ANOVA)

DLC Kesici Takım ve İşleme Parametrelerinin Yüzey Kalitesine ve Kesme Kuvvetlerine Etkilerinin İncelenmesi

Öz

Bu çalışmada, Al 7075 alaşımın Diamond Like Carbon (DLC)
kaplamalı kesici takımlarla frezelemede yüzey pürüzlülüğü ve kesme kuvvetleri
deneysel olarak incelenmiştir. İlerleme, devir ve talaş derinliğinin yüzey
pürüzlülüğüne ve kesme kuvvetlerine etkisi araştırılmıştır. Deney tasarımında Taguchi
metodu kullanılmıştır. Bu yöntem ile deneylere sarfadilecek zaman ve maliyetten
tasarruf edilmiş, deney neticelerinde elde edilen veriler optimize edilerek
iyileştirme gerçekleştirilmiştir. Bağımlı ve bağımsız değişkenler arasındaki
ilişki matematiksel olarak regresyon analiz yöntemiyle modellenmiştir. Sonuç
olarak da ANOVA ile de yüzeydeki pürüzlülüğün oluşumunda en etkili faktör %
92.46 ile ilerleme, kesme kuvveti oluşumunda en etkili faktör % 82.91 ile talaş
derinliği olduğu anlaşılmıştır. 
Regresyon analizi ile de Ra tahminsel denklemi % 94.7 doğruluk ile,  kuvvet tahminsel denklemi % 87.1 doğruluk ile
elde edilmiştir. Taguchi metodunun uygulandığı bu çalışmada kesme kuvveti ve
yüzey pürüzlülüğü gibi işleme yöntemlerinde en aza indirilip, performans yükseltilmiş
ve elde edilen ürün kalitesi iyileştirilmiştir.

Anahtar Kelimeler

DLC kaplı takımlar, Alüminyum 7075, Taguchi, Regrasyon Analizi, Varyans Analizi (ANOVA)

Kaynakça

• Kaya, H. Cengiz, A. Uçar, M. Talaş formuna bağlı olarak 7075 Al Alaşımının işlenebilirlik parametrelerinin uygunluğunun tespit edilmesi. 2. Ulusal Talaşlı İmalat Sempozyumu Konya. (77-91), (2010).
• Pınar, A.M. AA 6013 Alüminyum Alaşımının Frezelenmesinde Kesme Parametreleri Etkilerinin Ortalama ve Toplam Yüzey Pürüzlülüğü Kriterine Göre İncelenmesi. NWSA:Technological Applied Sciences, 5-1(15-2), (2010).
• Sekmen M., Günay M., Şeker U. Alüminyum Alaşımlarının İşlenmesinde Kesme Hızı ve Talaş Açısının Yüzey Pürüzlülüğü, Yığıntı Talaş ve Yığıntı Katmanı Oluşumu Üzerine Etkisi. Journal of Polytechnic, 18-3(141-148), (2015).
• Etyemez, A. Optimization of Effects of Pocket Tool Path Strategies and Cutting Parameters on Surface Quality. Acta Physica Polonica A, 129-4(886-889), (2016).
• Ay, M., Etyemez, A. Optimization of Effects of Cutting Parameters and Cutting Tool Path by using Grey Based Taguchi Method. Acta Physica Polonica, A, 134-1(125-128), (2018).
• Ay M., Karagöl T. Investigation of the machinability of the Al 7075 alloy using DLC coated cutting tools. Scientific Research and Essays, 6-1(44-51), (2011).
• List G., (2015).Wear behavior of cemented carbide tools in dry machining of aluminium alloy, Wear, 259:7-12, 1177-1189.
• Korkut I., Korkut, I., Donertas, M.A. The influence of feed rate and cutting speed on the cutting forces, surface roughness and tool–chip contact length during face milling. Materials and Design, 28 (308-312), (2007).
• Sevim, C., . Genç, O. Al-7075 Malzemesinin Freze Tezgâhında Delme İşleminde Farklı Devir Ve İlerleme Hızları İçin Oluşan Titreşimlerin İncelenmesi. International Journal Of Scientific& Technology Research, 4-4(50-57), (2015).
• Camposeco-Negrete C. Optimization of cutting parameters using Response Surface Method for minimizing energy consumption and maximizing cutting quality in turning of Liu Y, Meletis E, Erdemir A. A study on wear mechanism of diamond-like carbon films. Surf. Coatings Technol., 82(48-56), (1996).
• Settineri L, Bucciotti F, Cesano F, Faga MG. Surface Properties of Diamond Coatings for Cutting Tools. Ann. CIRP, 56(573-576), (2007).
• Trava-Airoldi VJ, Bonetti LF, Capote G, Santos LV, Corat EJ. A comparison of DLC film properties obtained by r.f. PACVD, IBAD, and enhanced pulsed-DC PACVD. Surf. Coatings Technol., 202(549-554), (2007).
• Uenga HY, Guob CT, Dittrich KH. Development of a hybrid coating process for deposition of diamond-like carbon films on microdrills. Surf. Coatings Technol., 200(2900-2908), (2007).
• Vandevelde TCS, Vandierendonck K, Van Stappen M, Du Mong W, Perremans P. Cutting applications of DLC, hard carbon and diamond films. Surf. Coatings Technol.,113(80-85), (1999).
• Deepak D., Rajendra B Investigations on the surface roughness produced in turning of Al 6061 (as-cast) by taguchi method. International Journal of Research in Engineering and Technology, 4-8(295-298), (2015).
• Chandra Sekhar, Y., Gopichand, A., Sam Sukumar, R., Pavan Kumar, N. Optimization of Surface Roughness of 6463 Aluminium Alloy and Brass Materials in CNC Milling Operation Using Taguchi’s Design. International Journal of Innovative Research in Science, Engineer ing and Technology, 6-2 (1553- 1560), (2017).
• Sakthivelu, S., Anandaraj, T., Selwin, M. Multi–Objective Optimization of Machining Conditions on Surface Roughness and MRR during CNC End Milling of Aluminium Alloy 7075 Using Taguchi Design of Experiments. Mechanics and Mechanical Engineering, 21-1(95–103), (2017).
• Saravanakumar, A., Sasikumar, P., Nilavusri, N. Optimization of Machining Parameters using Taguchi Method for Surface Roughness. J. Mater. En viron. Sci., 7-5(1556-1561), (2016).
• Yaşar, N., Yurtkuran, H., Günay, M. Sertleştirilmiş X40CrMoV5-1 Çeliğinin Tornalanmasında Kesme Kuvvetinin Deneysel ve Nümerik Olarak İncelenmesi. GU J Sci, Part C, 6-4 (765-773), (2018).
• Satish Kumar, M. D., Prasad, J., Abhishek Krishna, D., Venkat Narayana, M., Anusha, M., Saravanakumar A. Parametric optimization of aluminium alloy milling using Taguchi method for surface roughness. International Journal of Scientific Research and Review, 7-3(517-522), (2018).
• Ay, M., Altunpak, Y. Optimization of cutting parameters and graphite rate in drilling of a hybrid aluminium matrix composites. Journal of Engineering and Fundamentals, 2-2, (42-50), (2015).
• Ay, M., Basmacı, G. Investigation of The Effects of Conventional and Wiper Coated Carbide Tools With Dry Cutting on Cutting Forces, Surface Roughness and Material Hardness In Turning 17-4 Ph Stainless Steel. The Online Journal of Science and Technology, 6-1, (33-39), (2016).