The Effect of Different Cooling Methods to Hole Quality and Tool Life in the Drilling of AA7075 and AA2024 Aluminum Alloys

Yıl 2020, Cilt: 1 Sayı: 2, 1 - 13, 26.08.2020

Ayşegül Çakır Şencan , Abdullah Duran , Ulvi Şeker

Öz

Controlling the amount of the cutting fluid used in machining processes is important in terms of its effects on the environment, human health, and also on the total cost of production. In this study, the AA7075 and AA2024 aluminum alloys were subjected to drilling process using four different cooling conditions (internal MQL, external MQL, conventional cooling and compressed air cooling), four different cutting speeds (100, 125, 150, 175 m/min) and four different feed rates (0.10, 0.15, 0.20, 0.25 mm/rev). At the end of experiments which have been performed with respect to Taguchi experimental design method, in addition to the hole quality such as surface roughness of hole, diametrical deviation, ovality and axial deviation, wear/build-up edge on cutting tools were investigated. The obtained data were evaluated by performing ANOVA and Signal/Noise (S/N) tests. At the end of experiments, it was determined that cooling method has the most effect on output parameters. It was observed that while the lowest values were found at conventional cooling application, the results from the application of internal MQL were very similar to conventional cooling method. While increased feed rate generally caused increase in all the output parameters, the cutting speed has unclear effect on the test results. The results of the hole quality obtained from the AA7075 alloy were found to be better than the results obtained from the AA2024 alloy, especially in poor cooling conditions such as compressed air cooling and external MQL application.

Anahtar Kelimeler

Drilling, Hole quality, Cutting tool wear, MQL, Taguchi

Kaynakça

• 1. A. Çakır, AA7075 ve AA6013 Investigation of cutting parameter on aluminium alloys during drilling operations, Master Thesis, Gazi University, Graduate School of Natural and Applied Sciences, Ankara, Turkey, 2009.
• 2. H.A. Kishawy, M. Dumitrescu, E.G. Ng, M.A. Elbestawi, Effect of cutting fluid strategy on tool performance, chip morphology and surface quality during high-speed machining of A356 aluminum alloy, International Journal of Machine Tools and Manufacture, 45: 219–227, 2005.
• 3. P.S. Sreejith, Machining of 6061 aluminium alloy with MQL, dry and flooded lubricant conditions, Materials Letters, 62: 276–278, 2008.
• 4. L.N. L´opez de Lacalle, C. Angulo, A. Lamikiz, J. A. S´anchez, Experimental and numerical investigation of the effect of spray cutting fluids in high speed milling, Journal of Materials Processing Technology, 172(1), 11-15, 2006.
• 5. W. Zhong, D. Zhao, X. Wang, A comparative study on dry milling and little quantity lubricant milling based on vibration signals, International Journal of Machine Tools & Manufacture, 50: 1057-1064, 2010.
• 6. R. Cobden, Aluminium: Physical properties, characteristics and alloys. European Aluminium Association, Training in Aluminium Application Technologies (TALAT-1501), 36–252, 1994.
• 7. B. Mills, A. H. Redford, Machinability of Engineering Materials, Applied Sci. Publishers Ltd., New York, USA, 1983.
• 8. M. Akkurt, Metal Cutting Methods and Machine Tools, Birsen Press, 23-90, 117-181, Ankara, Turkey, 1998.
• 9. H.L. Tonshoff, W. Spintig, W. Konig, A. Neises, Machining of holes developments in drilling technology, Annals of the CIRP, 43 (2): 551-561, 1994.
• 10. C. Sanjay, C. Jyothi, A study of surface roughness in drilling using mathematical analysis and neural networks, The International Journal of Advanced Manufacturing Technology, 29:846-852, 2006.
• 11. M. Pirtini, I. Lazoglu, Forces and hole quality in drilling, International Journal of Machine Tools & Manufacture, 45(11): 1271-1281, 2005.
• 12. A. Thangaraj, P.K. Wright, Computer-assisted predicted of drill-failure using in-process measurements of thrust force, Journal of Engineering for Industry, 110(4): 192-200, 1988.
• 13. N. Tosun, M. Huseyinoglu, Effect of MQL on surface roughness in milling of AA7075-T6, Materials and Manufacturing Process, 25:793–798, 2010.
• 14. A. Çakır, Investigation of the effect of cooling conditions on cutting performance in drilling AA 7075 and AA 2024 aluminum materials, Ph.D Thesis, Gazi University, Graduate School of Natural and Applied Sciences, Ankara, Turkey, 2015.
• 15. A. Çakır, S. Yağmur, N. Kavak, G. Küçüktürk, U. Şeker, The effect of minimum quantity lubrication under different parameters in the turning of AA7075 and AA2024 aluminium alloys, The International Journal of Advanced Manufacturing Technology, 81: 1-4, 2015.
• 16. D.U. Braga, A.E. Diniz, G.W.A. Miranda, N.L. Coppini, Using a minimum quantity of lubricant (MQL) and a diamond coated tool in the drilling of aluminum–silicon alloys, Journal of Materials Processing Technology, 122(1):127–138, 2002.
• 17. E. Lugscheider, O. Knotek, C. Barimani, T. Leyendecker, O. Lemmer, R. Wenke, Investigations on hard coated reamers in different lubricant free cutting operations, Surface and Coatings Technology, 90(1-2): 172-177, 1997.
• 18. E.A. Rahim, H.A. Sasahara, A study of the effect of palm oil as MQL lubricant on high speed drilling of titanium alloys, Tribology International, 44: 309–317, 2011.
• 19. S. Bhowmick, A.T. Alpas, Minimum quantity lubrication drilling of aluminium– silicon alloys in water using diamond-like carbon coated drills, International Journal of Machine Tools and Manufacture, 48: 1429– 1443, 2008.
• 20. R. Autret, S.Y. Liang, Minimum quantity lubrication in finish hard turning. In: Proceedings of International Conference on Humanoid, Nano Technology, Information Technology, Communication and Control, Environment, and Management (HNICEM’03), Manila, Republic of the Philippines, 1–9, 2003.
• 21. N.R. Dhar, M. Kamruzzaman, M. Ahmed, Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel, Journal of Materials Processing Technology, 172: 299–304, 2006.
• 22. G. Le Coz, M. Marinescu, A. Davillez, D. Dudzinski, L. Velnom, Measuring temperature of rotating cutting tools: Application to MQL drilling and dry milling of aerospace alloys, Applied Thermal Engineering, 36: 434-441, 2012.
• 23. G. Fox-Rabinovich, J.M. Dasch, T. Wagg, K. Yamamoto, S. Veldhuis, G.K. Dospaeva, Cutting performance of different coatings during minimum quantity lubrication drilling of aluminum silicon B319 cast alloy, Surface and Coatings Technology, 205: 4107–4116, 2011.
• 24. A. Meena, M. El Mansori, Study of dry and minimum quantity lubrication drilling of novel austempered ductile iron (ADI) for automotive applications, Wear, 271: 2412– 2416, 2011.
• 25. A.E. Diniz, J.R. Ferreira, F.T. Filho, Influence of refrigeration/lubrication condition on SAE 52100 hardened steel turning at several cutting speeds, International Journal of Machine Tools and Manufacture, 43(3): 317-326, 2003.
• 26. U, Şeker, Design cutting tool in machining, Gazi University Graduate School of Natural and Applied Sciences, Training Notes, 39–45, Ankara, Turkey, 2000.
• 27. Y.S. Liao, H.M. Lin, Y.C. Chen, Feasibility study of the minimum quantity lubrication in high-speed end milling of NAK80 hardened steel by coated carbide tool, International Journal of Machine Tools and Manufacture, 47: 1667–1676, 2007.
• 28. V.S. Sharma, M. Dogra, N.M. Suri, Cooling techniques for improved productivity in turning, International Journal of Machine Tools and Manufacture, 49: 435–453, 2009.
• 29. E.M. Trent, Metal cutting, Page 1-171, Butterworths Press, London, 1989.
• 30. V.A. Rogov, G. Siamak, Optimization of surface roughness and vibration in turning of aluminum alloy AA2024 using Taguchi technique, International Journal of Mechanical, Aerospace, Industrial and Mechatronics Engineering, 7: 10-11, 2013.