AISI 1050 Çeliğinde Kesme Verimliliği ve Delik Kalitesini Artırmak için Delme Parametrelerinin Optimizasyonu
Abstract
Bu çalışma, AISI 1050 çeliğinde delme parametrelerinin kesme kuvvetleri ve delik kalitesi üzerindeki etkilerini kapsamlı bir istatistiksel analizle sunmaktadır. Çalışmada, çeşitli faktörlerin önemini değerlendirmek için Varyans Analizi (ANOVA) kullanılmıştır. Araştırma, matkap geometrisi, kesme hızı ve ilerleme hızının itme kuvveti, tork ve delik kalitesinin çeşitli metrikleri üzerindeki etkisini sistematik olarak incelemek amacıyla tam faktöriyel deney tasarımı kullanmaktadır. ANOVA sonuçları, matkap geometrisinin itme kuvveti ve torktaki varyansın önemli bir kısmını açıklayan baskın faktör olduğunu ve istatistiksel olarak anlamlı F-değerleri ile delme performansının optimizasyonundaki kritik rolünü doğruladığını göstermektedir. Ayrıca, kesme hızı ve ilerleme hızı da kesme kuvvetleri ve delik kalitesi metriklerindeki varyansa önemli katkılar sağlamaktadır. Bu bulgular, bu parametrelerin delme verimliliğini artırmada ve çapak oluşumu ile yüzey pürüzlülüğü gibi kusurları en aza indirmede önemini vurgulamaktadır. Bu parametreler arasındaki etkileşim, çalışmada kullanılan istatistiksel modelleme yaklaşımlarıyla kanıtlandığı üzere, optimal delme koşullarının elde edilmesi için esastır. ANOVA'ya ek olarak, çalışma bulguları daha da doğrulamak için Taguchi'nin sinyal-gürültü oranı analizini içermektedir. Bu yöntem, belirli matkap geometrilerinin delme sonuçlarındaki değişkenliği en aza indirmedeki üstün performansını vurgulamakta ve yüksek kaliteli delikler elde etmede matkap tasarımının önemini pekiştirmektedir. Bu araştırmadan elde edilen içgörüler, özellikle AISI 1050 gibi orta karbonlu çelikler için endüstriyel uygulamalarda delme süreçlerinin optimize edilmesi için sağlam bir temel sağlamakta ve işleme verimliliği ve kalitesini artırmayı amaçlayan gelecekteki araştırma çabalarına değerli rehberlik sunmaktadır. Çalışmanın etkileri, delme parametrelerinin etkileşimini anlamanın operasyonel verimlilikleri ve ürün kalitesini artırabileceği üretim alanındaki pratik uygulamalara kadar uzanmaktadır. Bulgular, delme performansını etkileyen kritik faktörleri açıklayarak, işleme ve malzeme işleme alanındaki daha ileri araştırmalar için bir referans noktası olarak mevcut bilgi birikimine katkıda bulunmaktadır.
References
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Optimization of Drilling Parameters and Tool Geometry for Enhanced Performance and Hole Quality in AISI 1050 Steel
Abstract
This study presents a comprehensive statistical analysis of the effects of drilling parameters on cutting forces and hole quality in AISI 1050 steel, utilizing Analysis of Variance (ANOVA) to evaluate the significance of various factors. The research employs a full factorial experimental design to systematically investigate the influence of drill geometry, cutting speed, and feed rate on thrust force, torque, and several metrics of hole quality. The ANOVA results indicate that drill geometry is the predominant factor, accounting for a significant portion of the variance in thrust force and torque, with statistically significant F-values, thereby confirming its critical role in drilling performance optimization. Moreover, cutting speed and feed rate also demonstrate substantial contributions to the variance in cutting forces and hole quality metrics. These findings highlight the importance of these parameters in enhancing drilling efficiency and minimizing defects such as burr formation and surface roughness. The interaction between these parameters is essential for achieving optimal drilling conditions, as evidenced by the statistical modeling approaches employed in the study. In addition to ANOVA, the study incorporates Taguchi method's signal-to-noise ratio analysis to further validate the findings. This method underscores the superior performance of specific drill geometries in minimizing variability in drilling outcomes, thereby reinforcing the significance of drill design in achieving high-quality holes. The insights derived from this research provide a robust foundation for optimizing drilling processes in industrial applications, particularly for medium-carbon steels like AISI 1050, and offer valuable guidance for future research endeavors aimed at enhancing machining efficiency and quality. The implications of this study extend to practical applications in manufacturing, where understanding the interplay of drilling parameters can lead to improved operational efficiencies and product quality. The findings contribute to the existing body of knowledge by elucidating the critical factors influencing drilling performance, thus serving as a reference point for further investigations in the field of machining and materials processing.
References
- G. Kannan, R. Thangaraju, Effect of industrial waste fly ash on the drilling characteristics of banana fiber residue reinforced polymer composites, Journal of Industrial Textiles, 51(2), (2022) 2665-2687.
- M.F. Ghazali, et al., Tool wear and surface evaluation in drilling fly ash geopolymer using HSS, HSS-Co, and HSS-TiN cutting tools, Materials, 14(7), 2021, 1628.
- R. Pramod, S. Basavarajappa, G.B.V. Kumar, Investigation on surface roughness of drilled holes in nanoparticle filled polymer matrix composites, Advances in Science and Technology, 105 (2021) 68-76.
- K. Giasin, et al., Evaluation of the Surface Defects and Dimensional Tolerances in Multi-Hole Drilling of AA5083, AA6061, and AA2024. Applied Sciences, 11(9), 2021, 4285.
- N.K. Kamble, V.S. Jatti, Optimization of drilling process parameter during of drilling of AISI 317L stainless steel, Engineering Research Express, 1(2), 2019, 025021.
- N. Mandal, S. Hloch, and A.K. Das, Comparison of maraging steel surface integrity in hybrid and conventional micro-ecdm processes, Materials, 15(13), 2022, 4378.
- D. Deepak, B.V. Rajendra, The effect of process parameters on material removal rate in drilling of Al 6061-SiC composite, Matec Web of Conferences, 144, 2018, 03009.
- S. Juneja, et al., Impact of process variables of acetone vapor jet drilling on surface roughness and circularity of 3D-printed ABS parts: Fabrication and Studies on Thermal, Morphological, and Chemical Characterizations. Polymers, 14(7), 2022, 1367.
- M. Yusof, H. Harun, R. Bahar, Experimental investigation of minimum quantity lubrication in meso-scale milling with varying tool diameter. IOP Conference Series Materials Science and Engineering, 290, 2018, 012035.
- A. Mohammed, et al., Sustainable machining of Mg-9Al-1.4Zn foam used for temporary biomedical implant using cryogenic cooling, Materials, 15(19), 2022, 6678.
- P. Saraswat, Experimental Investigation of Surface roughness and MRR in rotary-ultrasonic machining of float glass, Evergreen, 10(4), 2023, 2675-2682.
- R. Sahoo, et al., Fabrication of micro-hole using novel maglev EDM, Journal of Micromanufacturing, 6(2), 2022, 141-150.
- V.K. Singh, D. Joshi, P. Saraswat, A review on effect of process parameters on machining characteristics of rotary ultrasonic machine, Skit Research Journal, 10(2) 2020, 78.
- P. Chaitanya, Optimization of hole quality parameters using TOPSIS method in drilling of GFRP composite. International Journal of Science and Research Archive, 9(2), 2023, 030-038.
- M. Mudhukrishnan, et al., Optimization and sensitivity analysis of drilling parameters for sustainable machining of carbon fiber–reinforced polypropylene composites, Journal of Thermoplastic Composite Materials, 32(11), 2018, 1485-1508.
- Zhou, H., et al., Experimental research on new hole-making method assisted with asynchronous mixed frequency vibration in TiBw/TC4 composites, The International Journal of Advanced Manufacturing Technology, 125(1-2), 2022, 543-561.
- R. Shanmugam, et al., Machining temperature, surface integrity and burr size investigation during coolant-free hole milling in Ti6Al4V titanium alloy, Lubricants, 11(8), 2023, 349.
- J.U. Prakash, et al., Optimization of machining parameters in drilling of LM6/ C/Fly ash hybrid composites. Manufacturing Review, 9, 2022, 28.
- H.A Al-Tameemi, et al., Evaluation of cutting-tool coating on the surface roughness and hole dimensional tolerances during drilling of Al6061-T651 alloy, Materials 14(7), 2021, 1783.
- J.M. Susai, B.H. Sai, D. Dinakaran, Prediction and geometric adaptive control of surface roughness in drilling process. Fme Transaction, 47(3), 2019, 424-429.
- İ.B. Şahin, Urtekin, L., Genç, A., Özerkan, H. B., Optımızatıon of machining parameters for boron alloy steel by plunge electro erosion by taguchi technique, Journal of Scientific Reports-A, 50, (2022), 169-180.
- K.L. Kala, K.P. Rao, Experimental investigation on drilling of fiber metal laminates using grey based taguchi approach. Journal of Mines Metals and Fuels, 2022, 200-206.
- J.S.S. Babu, M. Heo, C.G. Kang, Study of machining parameter optimization in drilling of magnesium based hybrid composites reinforced with SiC/CNT, Key Engineering Materials, 846, 2020, 42-46.
- C.L.Tan, A.I. Azmi, N. Muhammad, Surface roughness analysis of carbon/glass hybrid polymer composites in drilling process based on taguchi and response surface methodology, Advanced Materials Research, 1119, 2015, 622-627.
- M. Aamir, et al., Optimization and modeling of process parameters in multi-hole simultaneous drilling using taguchi method and fuzzy logic approach. Materials, 13(3), 2020, 680.
- S. Arunachalam, S. Perumal, Investigation of effect of graphite particles on drillability of metal matrix composite, Materials Science, 22(3), 2016, 390-396.
- Ç. Bolat, Effect of drilling parameters and tool geometry on the thrust force and surface roughness of aerospace grade laminate composites. Micromachines 14 (7), (2023), 1427.
- R.J. Brook, G.C. Arnold, Applied regression analysis and experimental design, 2018: CRC Press.
- V. Alevizakos, R. Mosch, C.V. See, Influence of multiple used implant drills on their cutting performance and fracture resistance, Materials, 16(15), 2023, 5271.
- M.G. Fard, H. Baseri, A. Zolfaghari, Experimental Investigation of the effective parameters and performance of different types of structural tools in drilling CFRP/AL alloy stacks, Journal of Composite Materials, 56(29), 2022, 4461-4471.
- J. Fernández-Pérez, et al., Hybrid composite-metal stack drilling with different minimum quantity lubrication levels. Materials, 12(3), 2019, 448.
- H. Singh, B. Dewangan, P.K. Jain, Experimental study on drilling characteristics of the hybrid sisal–jute fibre epoxy composites, Journal of Micromanufacturing, 4(2), 2021, 157-168.
- A. Ellenberger, et al., Drilling of natural fiber-reinforced based polyurethane foam composite. Journal of Composite Materials, 56(6), 2022, 899-909.
- A. Scarano, F. Lorusso, S. Noumbissi, Infrared thermographic evaluation of temperature modifications induced during implant site preparation with steel vs. zirconia implant drill, Journal of Clinical Medicine, 9(1), 2020, 148.
- H.R. Maleki, et al., Experimental study on drilling of jute fiber reinforced polymer composites, Journal of Composite Materials, 53(3), 2018, 283-295.
- P. Hale, E. Ng, 3D Finite element model on drilling of CFRP with numerical optimization and experimental validation, Materials, 14(5), 2021, 1161.
Details
| Primary Language | English |
|---|---|
| Subjects | Optimization Techniques in Mechanical Engineering, Manufacturing Processes and Technologies (Excl. Textiles) |
| Journal Section | Research Articles |
| Authors | |
| Early Pub Date | April 30, 2025 |
| Publication Date | April 30, 2025 |
| Submission Date | November 5, 2024 |
| Acceptance Date | January 6, 2025 |
| Published in Issue | Year 2025 Volume: 6 Issue: 1 |
