Inconel 625 alaşımının seramik (sialon) takımla frezelenmesinde kesme kuvveti, takım ömrü/aşınmasi ve yüzey kalitesi karakteristiklerinin deneysel olarak araştırılması, sonlu elemanlar metoduyla kesme kuvveti ve sıcaklığın analizi
Yükleniyor...
Dosyalar
Tarih
2025
Yazarlar
Dergi Başlığı
Dergi ISSN
Cilt Başlığı
Yayıncı
Karabük Üniversitesi, Lisansüstü Eğitim Enstitüsü
Erişim Hakkı
info:eu-repo/semantics/openAccess
Özet
Bu çalışmada, deneysel ve sonlu elemanlar analizi ile düşük işlenebilirliğe sahip Inconel 625 süper alaşımların SiAlON seramik kesici takımlar kullanılarak işlenebilirliği araştırılmıştır. Inconel 625 süper alaşımları, yüksek sıcaklıklarda mükemmel çekme dayanımı, sürünme direnci ve oksidasyon/korozyon direnci sergilemeleri nedeniyle uzay/havacılık, enerji ve denizcilik gibi çeşitli endüstrilerde yaygın olarak tercih edilmektedir. Sergiledikleri üstün özellikler nedeniyle Inconel 625 alaşımlar düşük işlenebilirliğe sahiptir. Bu durum kesici takımların hızlı aşınmasına neden olarak iş parçası yüzey kalitesinin bozulmasına ve kesici takımın çok kısa sürede kullanılamaz hale gelmesine sebebiyet vermektedir. Dolayısıyla, Inconel 625 alaşımların işlenmelerinde performans iyileştirilmeleri yapmak, işleme
parameterlerini optimize etmek ve ideal kesici takım malzemesi ile geometrisini kullanmak önem arz etmektedir. Bu deneysel çalışmada son yıllarda kullanımı oldukça artan SiAlON seramik kesici takımlar frezeleme operasyonunda kullanılmak üzere tercih edilmiştir. Ham bir çubuk formunda temin edilen SiAlON malzemeler birçok prosesten geçirilerek nihai ürün parmak freze haline getirilmiştir. Deney tasarımı, Taguchi L9 ortogonal dizisi kullanılarak modellenmiş ve dokuz adet frezeleme deneyi üç farklı kesme hızı (160, 240 ve 360 m/dk), ilerleme miktarı (0.020, 0.030 ve 0.045 mm/diş) ve kesme derinliği (0.4, 0.6 ve 0.9 mm) seviyelerinde gerçekleştirilmiştir. Sonlu elemanlar analizleriyle kesme kuvveti ve sıcaklığı, deneysel çalışmalarla ise işleme parametrelerinin kesme kuvveti, yüzey pürüzlülüğü, takım ömrü, aşınma tipi ve mekanizmaları üzerindeki etkileri incelenmiştir. Kesme kuvveti ölçümlerinin gerçekleştirilmesi amacıyla dinamometre kullanılarak, kuru işleme koşulu altında aynı yönlü frezeleme deneyleri tamamlanmıştır. Deneysel çalışmalar kapsamında, kesici takımın çeşitli bölgelerinden taramalı elektron mikroskobu (SEM) ile görüntüler alınmış, kantitatif analizler ile kesici takımdaki yapışmaların kimyasal kompozisyonu belirlenmiştir. Talaş kaldırma işlemleri döngüler halinde gerçekleştirilmiş ve her bir döngü sonrası dijital mikroskop görüntüleri alınarak aşınma uzunlukları belirlenmiştir. Aşınma uzunluğu belirli bir seviyeye (0.35 mm) ulaştığında frezeleme operasyonları durdurulmuş ve kesici takımların kullanım ömrü tespit edilmiştir. Bulgular, etkisi incelenen ilerleme miktarı değerlerinin takım ömrü üzerinde en önemli etkiyi oluşturduğunu göstermiştir. Takım ömrü değerleri ile regresyon analizi gerçekleştirilerek Genişletilmiş Taylor Takım Ömrü denkleminde kullanılan katsayılar belirlenmiş ve takım ömrü tahminleri elde edilmiştir. Regresyon modelinin 99.34% etkiyle deneysel sonuçlarla uyum sağladığı ve modelin anlamlı olduğu belirlenmiştir. Kesici takımlarda baskın aşınma tipleri düşük kesme hızlarında yanak aşınması ve çıtlama, yüksek kesme hızlarında kırılma ve tüm koşullarda kendini gösteren yığma kenar olmuştur. Aşınma mekanizmalarının ise baskın olarak abrasiv ve adhesiv aşınmalar olduğu belirlenmiştir. Sonlu elemanlar analizleri ile deneysel çalışmalardan elde edilen kesme kuvveti değerleri arasında anlamlı bir uyum olduğu tespit edilmiştir.
In this study, the machinability of Inconel 625 superalloys with low machinability using SiAlON ceramic cutting tools was investigated via experiments and finite element analysis. Inconel 625 superalloys are widely preferred in various industries because of their superior mechanical properties at high temperatures. Owing to their superior properties, Inconel 625 alloys have low machinability. This situation causes rapid wear of the cutting tools, resulting in deterioration of the workpiece surface quality, and the cutting tool becomes unusable in a very short time. Therefore, it is important to improve the machining performance of Inconel 625 alloys, optimise the machining parameters and use the ideal cutting tool material and geometry. In our study, SiAlON ceramic cutting tools, which have been widely used in recent years, were preferred for use in milling operations. SiAlON materials, which are supplied in the form of a solid rod, are subjected to many processes and manufactured into a final product end mill. The experimental design was modelled via a Taguchi L9 orthogonal array, and nine milling experiments were carried out at three different cutting speeds (160, 240 and 360 m/min), feed rates (0.020, 0.030 and 0.045 mm/tooth) and depths of cut (0.4, 0.6 and 0.9 mm). Finite element analyses were performed on the cutting force and temperature, and experimental studies were carried out to investigate the effects of machining parameters on the cutting force, surface roughness, tool life, wear type and mechanism. To perform cutting force measurements, downmilling experiments were completed under dry conditions via a dynamometer. Within the scope of the experimental studies, scanning electron microscope (SEM) images were taken from various parts of the cutting tool, and the chemical composition of the adhesions on the cutting tool was determined via quantitative analyses. The machining operations were carried out in cycles, and the wear lengths were determined by taking digital microscope images after each cycle. When the wear length reached a specific level (0.35 mm), the milling operations were stopped, and the service life of the cutting tools was determined. The results revealed that the feed rate, the effect of which was analysed, had the most significant effect on tool life. Regression analysis was performed with the tool life values, the coefficients used in the extended Taylor tool life equation were determined, and tool life predictions were obtained. The regression model agreed with the experimental results, with an effect of 99.34%, and the model was significant. The predominant wear types of the cutting tools were flank wear and chipping at low cutting speeds, fracture at high cutting speeds and edge development under all conditions. The wear mechanism was determined to be predominantly abrasive and adhesive wear. It was determined that there was a significant agreement between the cutting force values obtained from finite element analyses and experimental studies.
In this study, the machinability of Inconel 625 superalloys with low machinability using SiAlON ceramic cutting tools was investigated via experiments and finite element analysis. Inconel 625 superalloys are widely preferred in various industries because of their superior mechanical properties at high temperatures. Owing to their superior properties, Inconel 625 alloys have low machinability. This situation causes rapid wear of the cutting tools, resulting in deterioration of the workpiece surface quality, and the cutting tool becomes unusable in a very short time. Therefore, it is important to improve the machining performance of Inconel 625 alloys, optimise the machining parameters and use the ideal cutting tool material and geometry. In our study, SiAlON ceramic cutting tools, which have been widely used in recent years, were preferred for use in milling operations. SiAlON materials, which are supplied in the form of a solid rod, are subjected to many processes and manufactured into a final product end mill. The experimental design was modelled via a Taguchi L9 orthogonal array, and nine milling experiments were carried out at three different cutting speeds (160, 240 and 360 m/min), feed rates (0.020, 0.030 and 0.045 mm/tooth) and depths of cut (0.4, 0.6 and 0.9 mm). Finite element analyses were performed on the cutting force and temperature, and experimental studies were carried out to investigate the effects of machining parameters on the cutting force, surface roughness, tool life, wear type and mechanism. To perform cutting force measurements, downmilling experiments were completed under dry conditions via a dynamometer. Within the scope of the experimental studies, scanning electron microscope (SEM) images were taken from various parts of the cutting tool, and the chemical composition of the adhesions on the cutting tool was determined via quantitative analyses. The machining operations were carried out in cycles, and the wear lengths were determined by taking digital microscope images after each cycle. When the wear length reached a specific level (0.35 mm), the milling operations were stopped, and the service life of the cutting tools was determined. The results revealed that the feed rate, the effect of which was analysed, had the most significant effect on tool life. Regression analysis was performed with the tool life values, the coefficients used in the extended Taylor tool life equation were determined, and tool life predictions were obtained. The regression model agreed with the experimental results, with an effect of 99.34%, and the model was significant. The predominant wear types of the cutting tools were flank wear and chipping at low cutting speeds, fracture at high cutting speeds and edge development under all conditions. The wear mechanism was determined to be predominantly abrasive and adhesive wear. It was determined that there was a significant agreement between the cutting force values obtained from finite element analyses and experimental studies.
Açıklama
Anahtar Kelimeler
Süper alaşımlar, SiAlON seramik, Frezeleme, Kesme kuvveti, Takım aşınması, Takım ömrü, Yüzey pürüzlülüğü., Superalloys, SiAlON ceramic, Milling, Cutting force, Tool wear, Tool life, Surface roughness.
