SavedAdd your journal

Journals / Politeknik Dergisi / 2024 / Cilt: 27 Sayı: 6

Experimental and Statistical Investigation of The Effects of Heat-Assisted Turning of AISI 4340 Steel on Dimensional Stability and Surface Roughness

AISI 4340 Çeliğinin Isı Destekli Tornalanmasının Boyutsal Kararlılık ve Yüzey Pürüzlülüğüne Etkilerinin Deneysel ve İstatistiksel İncelenmesi

Atakan Uğraş(Eskişehir Teknik Üniversitesi)0000-0002-8934-6125
Fırat Kafkas(GAZİ ÜNİVERSİTESİ, TEKNOLOJİ FAKÜLTESİ)0000-0003-3257-7413
Pages
2151–2159
Publication Date
2024-12-12
🏛️Bibliographic metadata and full text access for this article are provided via DergiPark.
DergiPark Record ↗
✨

AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

This makes it difficult to machine parts that have precise dimensional tolerances using the TIG-based HAM method.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:In this paper, to improve workpiece material dimensional stability properties and surface quality used heat-assisted machining method (HAM).
📊
Key Findings & Data:Through the HAM method, maximum reduction of 14.43% was achieved in the Pc value.
💡
Conclusion & Impact:This makes it difficult to machine parts that have precise dimensional tolerances using the TIG-based HAM method.
🔬Design:Araştırma Makalesi
📍Scope:Comprehensive Sample
⚙️Variables:Isı destekli işleme · Boyutsal kararlılık · Yüzey pürüzlülüğü

Abstract

In this paper, to improve workpiece material dimensional stability properties and surface quality used heat-assisted machining method (HAM). Power consumed for cutting (Pc, kW) and work material temperature (Tmr, °C) were determined by online measurements. In offline measurements deviation value in diameter measurement (DDM, µm) was determined by measuring workpiece diameter, and surface roughness (Ra, µm) was measured. Through the HAM method, maximum reduction of 14.43% was achieved in the Pc value. While the DDM value is 80 µm in conventional machining in the same cutting conditions, it decreases to 50 µm in the HAM method. While the surface roughness (Ra, µm) value is 2,66 µm in conventional machining, it decreases to 2,42 µm in the HAM method. According to the statistical analysis results, the most effective process parameter on the DDM value and surface roughness is the feed rate (f). It is followed by the processing method. The HAM method was found to have a significant effect on both. Since preheating cannot be done simultaneously with cutting, the heat produced causes expansion in the volume of the work material. This makes it difficult to machine parts that have precise dimensional tolerances using the TIG-based HAM method.

Özet

Bu çalışmada iş malzemesinin boyutsal kararlılık özelliklerini ve yüzey kalitesini iyileştirmek için ısı destekli işleme (IDİ) yöntemi kullanılmıştır. Çevrimiçi ölçümler yapılarak kesme için harcanan güç (Pc, kW) ve iş malzemesi sıcaklığı (Tmr, °C) belirlenmiştir. Çevrimdışı ölçümlerde iş parçası çapı ölçülerek çap ölçüsündeki sapma (ÇÖS, µm) değeri belirlenmiş ve yüzey pürüzlülüğü (Ra, µm) ölçülmüştür. IDİ yönteminde kesme için harcanan güç (Pc) değerinde maksimum %14,43 azalma sağlanmıştır. Aynı kesme şartlarında ÇÖS değeri konvansiyonel işlemede 80 µm olarak gerçekleşirken, IDİ yönteminde 50 µm’ a düşmektedir. Yüzey pürüzlülüğü (Ra, µm) konvansiyonel işlemede 2,66 µm olarak gerçekleşirken, IDİ yönteminde 2,42 µm’ a düşmektedir. İstatistiksel analiz sonuçlarına göre ÇÖS ve yüzey pürüzlülüğü üzerinde en etkili işlem parametresi ilerleme oranı (f) olmuştur. Ancak IDİ yönteminin her ikisi üzerinde önemli bir etkiye sahip olduğu görülmüştür. Ön ısıtma, kesme ile eş zamanlı yapılamadığı için üretilen ısı iş malzemesi hacminde genleşmeye neden olmaktadır. Bu durum TIG esaslı IDİ yöntemini kullanarak hassas boyutsal toleranslara sahip parçaların işlenmesini zorlaştırır.

🔖

Cite This Article

Uğraş, A., Kafkas, F. (2024). Experimental and Statistical Investigation of The Effects of Heat-Assisted Turning of AISI 4340 Steel on Dimensional Stability and Surface Roughness. Politeknik Dergisi, Cilt: 27 Sayı: 6, 2151–2159. https://doi.org/10.2339/politeknik.1409419

📄 Full Text PDF Viewer

📄

PDF görüntüleyici hazırlanıyor...

References (35)

  1. Ding H, Shin YC. "Laser-assisted machining of hardened steel parts with surface integrity analysis", International Journal of Machine tools and manufacture, 50:106114, (2010). https://doi.org/10.1016/j.ijmachtools.2009.09.001
  2. Zhao C, Xia Y, Chen X, Jiang Y, He Y, Pan S. "Thermal error detection and compensation technology for spindle of horizontal CNC machine tool with large torque", The International Journal of Advanced Manufacturing Technology, 107:85–96, (2020). https://doi.org/10.1007/s00170-020-05015-4
  3. Zahoor S, Mufti NA, Saleem MQ, Mughal MP, Qureshi MAM. "Effect of machine tool’s spindle forced vibrations on surface roughness, dimensional accuracy, and tool wear in vertical milling of AISI P20", The International Journal of Advanced Manufacturing Technology, 89:3671–3679, (2016). https://doi.org/10.1007/s00170-016-9346-1
  4. Pandey P, Gupta VK. "Duplex machining: An innovative approach for better dimensional accuracy and surface finish", International Journal of Machining and Machinability of Materials, 10:153–167, (2011). https://doi.org/10.1504/IJMMM.2011.040860
  5. Ali SHR, Mohamd OM. "Dimensional and geometrical form accuracy of circular pockets manufactured for aluminum, copper and steel materials on CNC milling machine using CMM", International Journal of Engineering Research in Africa, 17:64–73, (2015). https://doi.org/10.4028/www.scientific.net/JERA.17.64
  6. Tian A, Du X, Liu S, Jin S. "Characterization of Dimensional Variations in Turning Process for Multistep Rotary Shaft of High-Speed Motorized Spindle", Machines, 11:561, (2023). https://doi.org/10.3390/machines11050561
  7. Manikandan H, Chandra Bera T. "Modelling of dimensional and geometric error prediction in turning of thin-walled components", Precision Engineering, 72:382–396, (2021). https://doi.org/10.1016/j.precisioneng.2021.05.013
  8. Dhale SR, Deshmukh BB. "WEDM with different diameter wire electrodes on Inconel 718: Improved dimensional deviation, wire consumption and surface quality", Materials Today: Proceedings, 72:896–903, (2023). https://doi.org/10.1016/j.matpr.2022.09.088
  9. Zahoor S, Azam HA, Mughal MP, Ahmed N, Rehman M, Hussain A. "WEDM of complex profile of IN718: multi-objective GA-based optimization of surface roughness, dimensional deviation, and cutting speed", The International Journal of Advanced Manufacturing Technology, 114:2289–2307, (2021). https://doi.org/10.1007/s00170-021-06916-8
  10. Şahinoğlu A, Güllü A, "CuZn39Pb3 malzemenin torna tezgâhında işlenmesinde oluşan akım, ses şiddeti, titreşim ve yüzey pürüzlülük değeri arasındaki ilişkinin incelenmesi", Politeknik Dergisi, 23:615–624, (2020). https://doi.org/10.2339/politeknik.426106
  11. Dongre G, Rajurkar A, Patil S, Raut R, Joseph N, Mote V, "Effect of cooling technique and tool material on Ti6Al4V alloy", Materials Today: Proceedings, 80:1567–1572, (2023). https://doi.org/10.1016/j.matpr.2023.01.391
  12. Ahmadi Khatir F, Hossein Sadeghi M, Akar S. "Investigation of surface roughness in laser-assisted hard turning of AISI 4340", Materials Today: Proceedings, 38:3085–3090, (2020). https://doi.org/10.1016/j.matpr.2020.09.480
  13. Rao TB. "Reliability analysis of the cutting tool in plasma-assisted turning and prediction of machining characteristics", Australian Journal of Mechanical Engineering, 20:1020–1034, (2022). https://doi.org/10.1080/14484846.2020.1769458
  14. Ke J, Chen X, Liu C, Xu G, She Z, Zhang J, "Ultra-precision cutting characteristics of binderless tungsten carbide by in-heat-process laser-assisted diamond machining", International Journal of Refractory Metals and Hard Materials, 115:106311, (2023). https://doi.org/10.1016/j.ijrmhm.2023.106311
  15. Kainth, G. S., Chaturvedi MN. "Theoretical investigation of temperature in hot machining", International Journal of Machine Tool Design and Research, 156:241–256, (1975). https://doi.org/10.1016/0020-7357(75)90014-1
  16. Hameed S, Rojas HAG, Benavides JIP, Alberro AN, Egea AJS. "Influence of the regime of electropulsing-assisted machining on the plastic deformation of the layer being cut", Materials,11:1–11, (2018). https://doi.org/10.3390/ma11060886
  17. Kukliński M, Przestacki D, Bartkowska A, Kieruj P, Radek N. "Conventional and laser-assisted machining of laser-borided Monel 400 alloy", The International Journal of Advanced Manufacturing Technology, 126:5677–5687, (2023). https://doi.org/10.1007/s00170-023-11477-z
  18. Rao TB. "Reliability analysis of the cutting tool in plasma-assisted turning and prediction of machining characteristics", Australian Journal of Mechanical Engineering, 20:1020–1034, (2020). https://doi.org/10.1080/14484846.2020.1769458
  19. Wei C, Guo W, Pratomo ES, Li Q, Wang D, Whitehead D. "High speed, high power density laser-assisted machining of Al-SiC metal matrix composite with significant increase in productivity and surface quality", Journal of Materials Processing Technology, 285:116784, (2020). https://doi.org/10.1016/j.jmatprotec.2020.116784
  20. Hedberg GK, Shin YC, Xu L. "Laser-assisted milling of Ti-6Al-4V with the consideration of surface integrity", The International Journal of Advanced Manufacturing Technology, 79:1645–1658, (2015). https://doi.org/10.1007/s00170-015-6942-4
  21. Olsson M, Akujärvi V, Ståhl JE, Bushlya V. "Cryogenic and hybrid induction-assisted machining strategies as alternatives for conventional machining of refractory tungsten and niobium", International Journal of Refractory Metals and Hard Materials, 97:105520, (2021). https://doi.org/10.1016/j.ijrmhm.2021.105520
  22. Parida AK, Maity K. "Study of machinability in heat-assisted machining of nickel-base alloy", Measurement, 170:108682, (2021). https://doi.org/10.1016/j.measurement.2020.108682
  23. Çelebi A. "Deformation and Microstructural Analysis of Fiber Laser and TIG Welding of Thin Ti6Al4V Sheet by Coordinate Measurement Machine (CMM)", Politeknik Dergisi, 23:1183–1188, (2020). https://doi.org/10.2339/politeknik.581574
  24. Uğraş A, Kafkas F. "Isı destekli işlemede TIG tekniğinin uygulanabilirliği", 10 th Int. Congr. Mach., Antalya, 69–75(2019).
  25. Uğraş A, Kafkas F. "AISI 4340 çeliğinin ısı destekli işlenmesinde TIG tekniğinin uygulanabilirliği", 11th Int. Congr. Mach., Virtual, 245–252 (2021).
  26. Uğraş A, Kafkas F. "Sertleştirilmiş AISI 4340 çeliğin ısı -destekli işlenmesinde TIG tekniğinin uygulanabilirliği", İmalat Teknolojileri ve Uygulamaları,1:40–48(2020).
  27. Akdulum A, Kayır Y. "Investigation of the Effect of U Drills with Different Properties on Thrust Force, Torque and Spindle Load", Politeknik Dergisi, 26:387–400, (2023). https://doi.org/10.2339/politeknik.1113301
  28. Erdemir F, Özkan MT. "Application of Taguchi Method for Optimization of Design Parameters in Enhancement The Robust of “C” Type Snap-fits", Politeknik Dergisi, 25:1385–1395, (2022). https://doi.org/10.2339/politeknik.1076061
  29. Venkatesh KM, Kuppan P, Senthil KA, Ramesh KK, John RJ. "Effect of laser scan speed on surface temperature, cutting forces and tool wear during laser assisted machining of alumina", Procedia Engineering, 97:1647–1656, (2014). https://doi.org/10.1016/j.proeng.2014.12.315
  30. Callister WD, Rethwisch DG. "Materials Science and Engineering an Introduction", Eighth Edition, Wiley, USA, A29, (2007).
  31. Karpuschewski B, Kundrák J, Varga G, Deszpoth I, Borysenko D. "Determination of specific cutting force components and exponents when applying high feed rates", Procedia CIRP, 77:30–33, (2018). https://doi.org/10.1016/j.procir.2018.08.199
  32. O’Sullivan D, Cotterell M. "Temperature measurement in single point turning", Journal of materials processing technology, 118:301–308, (2001). https://doi.org/10.1016/S0924-0136(01)00853-6
  33. Carrino L, Giorleo G, Polini W, Prisco U. "Dimensional errors in longitudinal turning based on the unified generalized mechanics of cutting approach. Part I: Three-dimensional theory", International Journal of Machine Tools and Manufacture, 42:1517–1515, (2002). https://doi.org/10.1016/S0890-6955(02)00117-7
  34. Boothroyd G, Knight WA. "Fundamentals of Machining and Machine Tool", 3rd edition, CRC Press, USA, 82, (2006).
  35. Erdem S, Özdemir M, Rafighi M, Yavuz M. "1.2367 Sıcak İş Takım Çeliğinin Sert Tornalanmasında Kesme Parametrelerin Yüzey Pürüzlülüğü ve Kesme Kuvvetleri Üzerinde Etkisi", Politeknik Dergisi, 26:1071–1077, (2023). https://doi.org/10.2339/politeknik.1059568