INVESTIGATION THE EFFECTS OF SUSTAINABLE COOLING/LUBRICATION CONDITIONS ON THE MACHINABILITY OF Al-3Gr BASED HYBRID COMPOSITES

Yıl 2024, Cilt: 27 Sayı: 3, 688 – 705, 03.09.2024

Üsame Ali Usca , Ünal Değirmenci , Serhat Şap

https://doi.org/10.17780/ksujes.1400508

Öz

Bu araştırmanın temel amacı, son dönemde geliştirilen Al-3Gr bazlı hibrit kompozitlerden elde edilen çeşitli türevleri titizlikle değerlendirmek ve özellikle işlenebilirlik konusuna odaklanarak endüstriyel uygulamalara yönelik eksiklikleri tamamlamaktır. Değerlendirmeler, çeşitli kesme parametrelerini içeren bir bilgisayar sayısal kontrol (CNC) frezeleme aparatı kullanılarak gerçekleştirildi: değişen kesme hızları (150-225-300 m/dak), ilerleme hızları (0,15-0,225-0,300 mm/dev) ve çeşitli kesme parametreleri soğutma/yağlama koşulları (kuru-minimum miktarda yağlama-sıvı nitrojen). Deneysel çerçeve, % 95 güven seviyesinde kapsamlı bir varyans analizi (ANOVA) yoluyla daha da doğrulanan Taguchi L18 ortogonal dizisine dayalı olarak titizlikle yapılandırılmıştır. Deney boyunca kesme sıcaklığı, yan aşınma ve yüzey pürüzlülüğü gibi önemli işlenebilirlik parametreleri titizlikle incelendi. % 97’lik etkileyici bir hassasiyet düzeyi sergileyen optimize edilmiş test sonuçları, işlenebilirlikte yaklaşık % 18’lik bir azalmanın yanı sıra kesme sıcaklığında % 16, yan aşınma değerlerinde %16 ve yüzey pürüzlülüğünde % 25 oranında kayda değer bir azalma olduğunu ortaya çıkardı. Genel olarak bulgular, soğutma/yağlama koşullarının deneysel denemeler sırasında işlenebilirlik parametrelerini önemli ölçüde belirlediğini ortaya koyuyor. Bu deneylerden elde edilen ampirik kanıtlar, yeni Al-3Gr kompozitlerinin potansiyel kullanımını açıkça ortaya koymakta ve bunların endüstriyel alanlarda yaygın entegrasyonu için umut verici bir yol olduğunu göstermektedir.

Anahtar Kelimeler

Al-3Gr kompozitler, frezeleme, soğutma/yağlama, deney tasarımı, işlenebilirlik

Kaynakça

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  • Ande, R., Gulati, P., Kumar Shukla, D., & Dhingra, H. (2019). Microstructural and Wear Characteristics of Friction Stir Processed Al-7075/SiC Reinforced Aluminium Composite. Materials Today: Proceedings, 18, 4092-4101. doi:https://doi.org/10.1016/j.matpr.2019.07.353
  • Aslan, A., Salur, E., & Kuntoğlu, M. (2022). Evaluation of the Role of Dry and MQL Regimes on Machining and Sustainability Index of Strenx 900 Steel. Lubricants, 10(11). doi:10.3390/lubricants10110301
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INVESTIGATION THE EFFECTS OF SUSTAINABLE COOLING/LUBRICATION CONDITIONS ON THE MACHINABILITY OF Al-3Gr BASED HYBRID COMPOSITES

Yıl 2024, Cilt: 27 Sayı: 3, 688 – 705, 03.09.2024

Üsame Ali Usca , Ünal Değirmenci , Serhat Şap

https://doi.org/10.17780/ksujes.1400508

Öz

The main purpose of this research is to meticulously evaluate various derivatives resulting from recently developed Al-3Gr-based hybrid composites and to complete the deficiencies for industrial applications, especially focusing on processability. Assessments were conducted using a computer numerical control (CNC) milling apparatus, involving a spectrum of cutting parameters: varying cutting speeds (150-225-300 m/min), feed rates (0.15-0.225-0.3 mm/rev), and diverse cooling/lubrication conditions (dry-minimum quantity lubrication-liquid nitrogen). The experimental framework was meticulously structured based on the Taguchi L18 orthogonal array, which was further validated through a comprehensive analysis of variance (ANOVA) at a 95% confidence level. Throughout the experimentation, crucial machinability parameters such as cutting temperature, flank wear, and surface roughness were meticulously scrutinized. The optimized test outcomes, demonstrating an impressive precision level of 97%, revealed a reduction in machinability by approximately 18%, accompanied by a noteworthy decrease in cutting temperature by 16%, flank wear values by 16%, and surface roughness by 25%. Overall, the findings elucidate that the cooling/lubrication conditions significantly dictated the machinability parameters during the experimental trials. The empirical evidence extracted from these experiments emphatically suggests the potential utilization of the novel Al-3Gr composites, signifying a promising avenue for their widespread integration within industrial domains.

Anahtar Kelimeler

Al-3Gr composites, milling, cooling/lubrication, design of experiments, machinability

Kaynakça

  • Ahmad-Yazid, A., Taha, Z., Almanar, I. P., & Essays. (2010). A review of cryogenic cooling in high speed machining (HSM) of mold and die steels. Scientific Research, 5(5), 412-427.
  • Amiril, S. A. S., Rahim, E. A., & Syahrullail, S. (2017). A review on ionic liquids as sustainable lubricants in manufacturing and engineering: Recent research, performance, and applications. Journal of Cleaner Production, 168, 1571-1589. doi:https://doi.org/10.1016/j.jclepro.2017.03.197
  • Ande, R., Gulati, P., Kumar Shukla, D., & Dhingra, H. (2019). Microstructural and Wear Characteristics of Friction Stir Processed Al-7075/SiC Reinforced Aluminium Composite. Materials Today: Proceedings, 18, 4092-4101. doi:https://doi.org/10.1016/j.matpr.2019.07.353
  • Aslan, A., Salur, E., & Kuntoğlu, M. (2022). Evaluation of the Role of Dry and MQL Regimes on Machining and Sustainability Index of Strenx 900 Steel. Lubricants, 10(11). doi:10.3390/lubricants10110301
  • Babu, M. N., Anandan, V., Yıldırım, Ç. V., Babu, M. D., & Sarıkaya, M. (2022). Investigation of the characteristic properties of graphene-based nanofluid and its effect on the turning performance of Hastelloy C276 alloy. Wear, 510-511, 204495. doi:https://doi.org/10.1016/j.wear.2022.204495
  • Benzait, Z., & Trabzon, L. (2018). A review of recent research on materials used in polymer–matrix composites for body armor application. Journal of Composite Materials, 52(23), 3241-3263. doi:10.1177/0021998318764002
  • Bhushan, R. K. (2013). Multiresponse Optimization of Al Alloy-SiC Composite Machining Parameters for Minimum Tool Wear and Maximum Metal Removal Rate. Journal of Manufacturing Science and Engineering, 135(2). doi:10.1115/1.4023454
  • Binali, R., Demirpolat, H., Kuntoğlu, M., & Sağlam, H. (2023). Machinability Investigations Based on Tool Wear, Surface Roughness, Cutting Temperature, Chip Morphology and Material Removal Rate during Dry and MQL-Assisted Milling of Nimax Mold Steel. Lubricants, 11(3), 101. Retrieved from https://www.mdpi.com/2075-4442/11/3/101
  • Cai, C., Liang, X., An, Q., Tao, Z., Ming, W., & Chen, M. (2021). Cooling/Lubrication Performance of Dry and Supercritical CO2-Based Minimum Quantity Lubrication in Peripheral Milling Ti-6Al-4V. International Journal of Precision Engineering and Manufacturing Technology, 8(2), 405-421. doi:10.1007/s40684-020-00194-7
  • Courbon, C., Pusavec, F., Dumont, F., Rech, J., & Kopac, J. (2013). Tribological behaviour of Ti6Al4V and Inconel718 under dry and cryogenic conditions—Application to the context of machining with carbide tools. Tribology International, 66, 72-82. doi:https://doi.org/10.1016/j.triboint.2013.04.010
  • Das, B., Roy, S., Rai, R. N., & Saha, S. C. (2016). Study on machinability of in situ Al–4.5%Cu–TiC metal matrix composite-surface finish, cutting force prediction using ANN. CIRP Journal of Manufacturing Science and Technology, 12, 67-78. doi:https://doi.org/10.1016/j.cirpj.2015.10.002
  • Değirmenci, Ü., Usca, Ü. A., & Şap, S. (2023). Machining characterization and optimization under different cooling/lubrication conditions of Al-4Gr hybrid composites fabricated by vacuum sintering. Vacuum, 208, 111741. doi:https://doi.org/10.1016/j.vacuum.2022.111741
  • Dhar, N. R., Ahmed, M. T., & Islam, S. (2007). An experimental investigation on effect of minimum quantity lubrication in machining AISI 1040 steel. International Journal of Machine Tools and Manufacture, 47(5), 748-753. doi:https://doi.org/10.1016/j.ijmachtools.2006.09.017
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  • Li, J., & Laghari, R. A. (2019). A review on machining and optimization of particle-reinforced metal matrix composites. The International Journal of Advanced Manufacturing Technology, 100(9), 2929-2943. doi:10.1007/s00170-018-2837-5
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  • López de Lacalle, L. N., Angulo, C., Lamikiz, A., & Sánchez, J. A. (2006). Experimental and numerical investigation of the effect of spray cutting fluids in high speed milling. Journal of Materials Processing Technology, 172(1), 11-15. doi:https://doi.org/10.1016/j.jmatprotec.2005.08.014
  • Maiarù, M., D'Mello, R. J., & Waas, A. M. (2018). Characterization of intralaminar strengths of virtually cured polymer matrix composites. Composites Part B: Engineering, 149, 285-295. doi:https://doi.org/10.1016/j.compositesb.2018.02.018
  • Mia, M., Gupta, M. K., Lozano, J. A., Carou, D., Pimenov, D. Y., Królczyk, G., . . . Dhar, N. R. (2019). Multi-objective optimization and life cycle assessment of eco-friendly cryogenic N2 assisted turning of Ti-6Al-4V. Journal of Cleaner Production, 210, 121-133. doi:https://doi.org/10.1016/j.jclepro.2018.10.334
  • Muthukrishnan, N., & Davim, J. P. (2011). An investigation of the effect of work piece reinforcing percentage on the machinability of Al-SiC metal matrix composites. Journal of Mechanical Engineering Research, 3(1), 15-24.
  • Muthukrishnan, N., Murugan, M., & Prahlada Rao, K. (2008). Machinability issues in turning of Al-SiC (10p) metal matrix composites. The International Journal of Advanced Manufacturing Technology, 39(3), 211-218. doi:10.1007/s00170-007-1220-8
  • Oguntuyi, S. D., Johnson, O. T., Shongwe, M. B., Jeje, S. O., & Rominiyi, A. L. (2021). The effects of sintering additives on the ceramic matrix composite of ZrO2: microstructure, densification, and mechanical properties – a review. Advances in Applied Ceramics, 120(5-8), 319-335. doi:10.1080/17436753.2021.1953845
  • Ozben, T., Kilickap, E., & Çakır, O. (2008). Investigation of mechanical and machinability properties of SiC particle reinforced Al-MMC. Journal of Materials Processing Technology, 198(1), 220-225. doi:https://doi.org/10.1016/j.jmatprotec.2007.06.082
  • Prasad, D. S., Shoba, C., & Ramanaiah, N. (2014). Investigations on mechanical properties of aluminum hybrid composites. Journal of Materials Research and Technology, 3(1), 79-85. doi:https://doi.org/10.1016/j.jmrt.2013.11.002
  • Ramanathan, A., Krishnan, P. K., & Muraliraja, R. (2019). A review on the production of metal matrix composites through stir casting – Furnace design, properties, challenges, and research opportunities. Journal of Manufacturing Processes, 42, 213-245. doi:https://doi.org/10.1016/j.jmapro.2019.04.017
  • Salur, E. (2022). Understandings the tribological mechanism of Inconel 718 alloy machined under different cooling/lubrication conditions. Tribology International, 174, 107677. doi:https://doi.org/10.1016/j.triboint.2022.107677
  • Salvi, H., Vesuwala, H., Raval, P., Badheka, V., & Khanna, N. (2023). Sustainability analysis of additive + subtractive manufacturing processes for Inconel 625. Sustainable Materials and Technologies, 35, e00580. doi:https://doi.org/10.1016/j.susmat.2023.e00580
  • Samy, G. S., Thirumalai Kumaran, S., & Uthayakumar, M. (2017). An analysis of end milling performance on B4C particle reinforced aluminum composite. Journal of the Australian Ceramic Society, 53(2), 373-383. doi:10.1007/s41779-017-0046-6
  • Shah, P., Khanna, N., & Chetan. (2020). Comprehensive machining analysis to establish cryogenic LN2 and LCO2 as sustainable cooling and lubrication techniques. Tribology International, 148, 106314. doi:https://doi.org/10.1016/j.triboint.2020.106314
  • Sharma, R., Singh, A. K., Arora, A., Pati, S., & De, P. S. (2019). Effect of friction stir processing on corrosion of Al-TiB2 based composite in 3.5 wt.% sodium chloride solution. Transactions of Nonferrous Metals Society of China, 29(7), 1383-1392. doi:https://doi.org/10.1016/S1003-6326(19)65045-4
  • Sozhamannan, C. G., Naveenkumar, K., Mathiarasu, A., Velmurugan, K., & Venkatachalapathy, V. S. K. (2018). Machining characteristics of Al/Ticp/Gr hybrid composites. Materials Today: Proceedings, 5(2, Part 1), 5940-5946. doi:https://doi.org/10.1016/j.matpr.2017.12.195
  • Srivastava, A. K., Dixit, A. R., & Tiwari, S. (2018). A review on the intensification of metal matrix composites and its nonconventional machining. Science and Engineering of Composite Materials, 25(2), 213-228. doi:doi:10.1515/secm-2015-0287
  • Suresh, P., Marimuthu, K., Ranganathan, S., & Rajmohan, T. (2014). Optimization of machining parameters in turning of Al-SiC-Gr hybrid metal matrix composites using grey-fuzzy algorithm. Transactions of Nonferrous Metals Society of China, 24(9), 2805-2814. doi:https://doi.org/10.1016/S1003-6326(14)63412-9
  • Şap, E., Usca, U. A., Gupta, M. K., & Kuntoğlu, M. (2021). Tool wear and machinability investigations in dry turning of Cu/Mo-SiCp hybrid composites. The International Journal of Advanced Manufacturing Technology, 114(1), 379-396.
  • Şap, E., Usca, Ü. A., Gupta, M. K., Kuntoğlu, M., Sarıkaya, M., Pimenov, D. Y., & Mia, M. (2021). Parametric optimization for improving the machining process of cu/mo‐sicp composites produced by powder metallurgy. Materials, 14(8). doi:10.3390/ma14081921
  • Şap, S. (2023a). Machining and Energy Aspect Assessment with Sustainable Cutting Fluid Strategies of Al–12Si Based Hybrid Composites. International Journal of Precision Engineering and Manufacturing-Green Technology, 11, 33-53. doi:10.1007/s40684-023-00544-1
  • Şap, S. (2023b). Understanding the Machinability and Energy Consumption of Al-Based Hybrid Composites under Sustainable Conditions. Lubricants, 11(3), 111. doi:https://doi.org/10.3390/lubricants11030111
  • Şap, S., Değirmenci, Ü., & Usca, Ü. A. (2023). Impact of boron nitride and silicon carbide on tribological properties of Al-3Gr-based hybrid composites. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 45(10), 510. doi:10.1007/s40430-023-04448-8
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Toplam 64 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Triboloji, Kompozit ve Hibrit Malzemeler, Makine İle İşleme
BölümMalzeme Bilimi ve Mühendisliği
Yazarlar

Üsame Ali Usca BİNGÖL ÜNİVERSİTESİ, MÜHENDİSLİK-MİMARLIK FAKÜLTESİ 0000-0001-5160-5526 Türkiye

Ünal Değirmenci BİNGÖL ÜNİVERSİTESİ, BİNGÖL TEKNİK BİLİMLER MESLEK YÜKSEKOKULU 0000-0003-1480-2488 Türkiye

Serhat Şap BİNGÖL ÜNİVERSİTESİ, BİNGÖL TEKNİK BİLİMLER MESLEK YÜKSEKOKULU 0000-0001-5177-4952 Türkiye

Yayımlanma Tarihi3 Eylül 2024
Gönderilme Tarihi5 Aralık 2023
Kabul Tarihi29 Mayıs 2024
Yayımlandığı Sayı Yıl 2024Cilt: 27 Sayı: 3

Kaynak Göster

APAUsca, Ü. A., Değirmenci, Ü., & Şap, S. (2024). INVESTIGATION THE EFFECTS OF SUSTAINABLE COOLING/LUBRICATION CONDITIONS ON THE MACHINABILITY OF Al-3Gr BASED HYBRID COMPOSITES. Kahramanmaraş Sütçü İmam Üniversitesi Mühendislik Bilimleri Dergisi, 27(3), 688-705. https://doi.org/10.17780/ksujes.1400508

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