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Al-4.5%Cu/TiB2/3p MMK'nın Çok Katmanlı Kaplamalı Kesici Takımlarla İşlenebilirliğinin Karşılaştırılması: Doğrulanmış FEM ve İstatistiksel Yaklaşımlar

Year 2024, Volume: 65 Issue: 714, 49 - 77, 29.04.2024

Erkan Öztürk

https://doi.org/10.46399/muhendismakina.1329342

Abstract

Alüminyum bazlı Metal Matris Kompozitler (MMK), yüksek mukavemet, sertlik ve düşük ağırlık gibi daha iyi mekanik ve fiziksel özelliklerinden dolayı metal kesme uygulamalarında yaygın olarak kullanılmaktadır. Ayrıca, modern kaplama uygulamaları, özellikle çok katmanlı kaplamalı takımlar, kesici takım performanslarını iyileştirerek MMK'ları işleme konusundaki zorlukları ortadan kaldırmada üstün bir potansiyele sahiptir. Bu nedenle, çalışmada, doğrulanmış FEM ve istatistiksel yaklaşımla çok katmanlı kaplamalı semente karbür bir kesici takımın Al-4.5%Cu/TiB2/3p MMK’nın tornalama performansını ortaya çıkarmak amaçlanmıştır. Deneysel olarak kalibre edilmiş ve seçilmiş bir similasyon için farklı kalınlık ve dizilimlerde (iki adet yumuşak ve üç adet sert kaplama malzemesi için) istatiksel olarak similasyon tasarımı kurulmuştur. Gri İlişki Analizi (GRA) yardımı ile MMK malzemenin tornalanmasında çok katmanlı kaplamalı uç performansını kesme kuvvetlerinin bileşkesi (FR) ve maksimum uç sıcaklığı (Tmax) baz alınarak araştırılmıştır. Optimum çok katmanlı kaplama, kaplama malzemeleri faktörleri için 4-2-4-3-2 seviyelerinde bulunmuş olup bu koşul sırasıyla: tungsten disülfid (WS2), molibden disülfür (MoS2), titanyum nitrür (TiN), alüminyum oksit (Al2O3), ve titanyum karbo-nitrürdür (TiCN). Her bir faktörün katkı oranları, Genel Doğrusal Model (GLM) ile incelenmiş, WS2 ve Al2O3 kaplama malzemeleri için sırasıyla %47,13 ve %24,43 oranında anlamlı olduğu tespit edilmiştir. Gelecekte çok katmanlı kaplamalar, MMK'ların işlenmesindeki zorlukları aşmak için değerli bir çözüm olabilirler.

Keywords

Çok katmanlı kaplamalı Kesici Takım Sonlu Elemanlar Yöntemi Gri İlişkisel Analiz

Supporting Institution

Yok

Project Number

Yok

Thanks

YOK

References

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Comparison of Machinability of Al-4.5%Cu/TiB2/3p MMC for Multi-Layer Coated Insert: Validated FEM and Statistical Approaches

Year 2024, Volume: 65 Issue: 714, 49 - 77, 29.04.2024

Erkan Öztürk

https://doi.org/10.46399/muhendismakina.1329342

Abstract

Aluminum-based Metal Matrix Composites (MMC) are commonly used in metal-cutting applications due to their better mechanical and physical properties, such as high strength, hardness, and low weight. Also, modern coating applications, especially multi-layer coated tools, have the cutting-edge potential for relieving the difficulties of machining MMCs to improve insert performances. Therefore, this study aimed to reveal the turning Al-4.5%Cu/TiB2/3p performance of the multi-layer coated cemented carbide insert with verified FEM and statistical approaches. Different coating materials, two and three of which were soft and hard, were appointed at different thicknesses and sequences in the design of experimentally calibrated simulations. The Grey Relation Analysis (GRA) was set to investigate the multi-layer coated insert performance for turning the MMC concerning the resultant cutting forces (FR) and maximum insert temperature (Tmax). The optimal multi-layered coating was found at levels 4-2-4-3-2 for the factors of coating materials: tungsten disulfide (WS2), molybdenum disulfide (MoS2), titanium nitride (TiN), aluminum oxide (Al2O3), and titanium carbo-nitride (TiCN), respectively. The contribution rates of each factor were significant concerning General Linear Model (GLM) at 47.13% and 24.43% for WS2 and Al2O3 coatings materials, respectively. In the future, multi-layered coatings can be a valuable solution for the difficulties of machining the MMCs.

Keywords

Multi-layer coated tool Finite Element Method Grey Relation Analysis

Project Number

Yok

References

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  • Baris, O., & Levent, U. (2021). Optimization of cutting forces on turning of Ti-6Al-4V Alloy by 3D FEM simulation analysis. Journal of Engineering Research and Applied Science, 10(2). Retrieved from https://www.journaleras.com/index.php/jeras/article/view/256
  • Bathula, D. B., Buddi, T., Shagwira, H., Mwema, F. M., & Rajesh, K. V. D. (2022). Analysis on behavior of Ti-6al-4v & Ti-5553 by performing turning operation using deform-3d. Advances in Materials and Processing Technologies, 1-18. doi: https://doi.org/10.1080/2374068X.2022.2037064
  • Bhushan, R. K. (2021). Multi-Response Optimization of Parameters during Turning of AA7075/SiC Composite for Minimum Surface Roughness and Maximum Tool Life. Silicon, 13(9), 2845-2856. doi: https://link.springer.com/article/10.1007/s12633-020-00640-w
  • Bobrovskij, I., Khaimovich, A., Bobrovskij, N., Travieso-Rodriguez, J. A., & Grechnikov, F. (2022). Derivation of the Coefficients in the Coulomb Constant Shear Friction Law from Experimental Data on the Extrusion of a Material into V-Shaped Channels with Different Convergence Angles: New Method and Algorithm. Metals, 12(2). doi: https://doi.org/10.3390/met12020239
  • Channabasavaraja, H. K., Nagaraj, P. M., & Srinivasan, D. (2016). Determination of Optimum Cutting Parameters for Surface Roughness in Turning AL-B4C Composites. International Conference on Advances in Materials and Manufacturing Applications (Iconamma-2016), 149. doi: https://iopscience.iop.org/article/10.1088/1757-899X/149/1/012029
  • Chen, J. P., Gu, L., & He, G. J. (2020). A review on conventional and nonconventional machining of SiC particle-reinforced aluminium matrix composites. Advances in Manufacturing, 8(3), 279-315. doi: https://link.springer.com/article/10.1007/s40436-020-00313-2
  • Chen, X., Xie, L., Xue, X., & Wang, X. (2017). Research on 3D milling simulation of SiCp/Al composite based on a phenomenological model. The International Journal of Advanced Manufacturing Technology, 92(5), 2715-2723. doi: https://doi.org/10.1007/s00170-017-0315-0
  • Choi, S. W. (2020). Influences of Precipitation of Secondary Phase by Heat Treatment on Thermal Properties of Al-4.5%Cu Alloy. KOREAN JOURNAL OF MATERIALS RESEARCH,30(8), 435-440. doi: https://doi.org/10.3740/MRSK.2020.30.8.435
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  • Das, D., & Chakraborty, V. (2018). Dry condition machining performance of T6 treated aluminium matrix composites. Materials Today-Proceedings, 5(9), 20145-20151. doi: https://doi.org/10.1016/j.matpr.2018.06.383
  • Denkena, B., Tonshoff, H. K., & Boehnke, D. (2005). An assessment of the machinability of iron-rich iron-aluminium alloys. Steel Research International, 76(2-3), 261-264. doi: https://doi.org/10.1002/srin.200506007
  • Du, Q., Eskin, D., & Katgerman, L. (2006). Modelling macrosegregation during DC casting of a binary aluminium alloy. Modeling of Casting, Welding and Advanced Solidification Processes - XI, 1, 235-242. doi: https://link.springer.com/article/10.1007/s11661-006-9042-0
  • Ghandehariun, A., Kishawy, H. A., Umer, U., & Hussein, H. M. (2016). Analysis of tool-particle interactions during cutting process of metal matrix composites. International Journal of Advanced Manufacturing Technology, 82(1-4), 143-152. doi: https://link.springer.com/article/10.1007/s00170-015-7346-1
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There are 59 citations in total.

Details

Primary Language English
Subjects Mechanical Engineering (Other)
Journal Section Research Article
Authors

Erkan Öztürk 0000-0002-7056-718X

Project Number Yok
Early Pub Date March 29, 2024
Publication Date April 29, 2024
Submission Date July 18, 2023
Acceptance Date November 24, 2023
Published in Issue Year 2024 Volume: 65 Issue: 714

Cite

APA Öztürk, E. (2024). Comparison of Machinability of Al-4.5%Cu/TiB2/3p MMC for Multi-Layer Coated Insert: Validated FEM and Statistical Approaches. Mühendis Ve Makina, 65(714), 49-77. https://doi.org/10.46399/muhendismakina.1329342
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