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Mikro-Frezeleme Yöntemi ile İşlenen İnce Duvarlı Yapılarda Deformasyonun İncelenmesi

Yıl 2023, Cilt: 4 Sayı: 1, 134 - 146, 26.06.2023
https://doi.org/10.55546/jmm.1200156

Öz

Mikro ince duvarlı yapılara, savunma, havacılık ve biyomedikal sektörlerinde mikro pompalar, mikro kanallı soğutucu plakalar, mikro kalıplarda sıklıkla rastlanılmaktadır. Mikro ince duvarlı yapıları elde etmek için sıklıkla kullanılan mikro mekanik işleme yöntemlerinden biri, mikro frezelemedir. Mikro frezeleme yöntemi, mikro bileşenleri yüksek doğrulukta ve iyi bir yüzey kalite elde ederek işlemeyi mümkün kılar. Fakat ince duvar geometrilerinin mikro frezelenmesinde dikkat edilmesi gereken birçok husus vardır. Bu çalışmada Al6061-T6 malzemesi mikro frezeleme işlemine tabi tutularak ince duvar yapıları elde edilmiştir. Mikro frezeleme deneylerinde farklı ilerleme hızları uygulanarak, ilerleme hızının duvar deformasyonuna etkisi incelenmiştir. Duvar deformasyonu ölçümlerinde optik profilometre cihazı kullanılarak duvar boyunca alınan ölçümler karşılaştırılmıştır. İlerleme hızının artmasıyla duvar deformasyonununda arttığı görülmüş, bu sonuçlar kesme kuvvetleri ile doğrulanmıştır. Mikro ince duvarın giriş ve çıkış bölgelerinde deformasyonun fazla olduğu görülmüştür. Ayrıca mikro ince duvarın üst noktasından alt noktalara doğru inildikçe, duvar deformasyonun azaldığı da elde edilen bulgular arasındadır.

Destekleyen Kurum

TÜBİTAK ve Afyon Kocatepe Üniversitesi Bilimsel Araştırma Projeleri Birimi

Proje Numarası

Tübitak 122M223 , BAP 22.Fen.Bil.22

Teşekkür

Bu çalışma Afyon Kocatepe Üniversitesi Bilimsel Araştırma Projeleri Koordinasyon Birimi tarafından 22.Fen.Bil.22 proje numaralı ve TÜBİTAK 1002 122M223 numaralı Hızlı Destek projesi ile desteklenmiştir. Kurumlara desteklerinden dolayı teşekkür ederiz.

Kaynakça

  • Akram S., Jaffery S. H. I., Khan M., Fahad M., Mubashar A., Ali L., Numerical and Experimental Investigation of Johnson Cook Material Models for Aluminum (Al 6061-T6) Alloy Using Orthogonal Machining Approach. Advanced of Mechanical Engineering 10(9), 1-14, 2018.
  • Aslantas K., Alatrushi L. K. H., Bedir F., et. al., An Experimental Analysis of Minimum Chip Thickness in Micro-milling of Two Different Titanium Alloys. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234(12), 1-13, 2020.
  • Aslantas K., Alatrushi L. K. H., Experimental Study on the Effect of Cutting Tool Geometry in Micro-milling of Inconel 718. Arabian Journal for Science and Engineering 46(3), 2327-2342, 2021.
  • Aslantas K., Çiçek A., The Effects of Cooling/lubrication Techniques on Cutting Performance in Micro-milling of Inconel 718 Superalloy. Procedia CIRP 77, 70-73,2018.
  • Aslantas K., Danish M., Hasçelik A., Mia M., Gupta M., Ginta T., Ijaz H., Investigations on Surface Roughness and Tool Wear Characteristics in Micro-turning of Ti-6Al-4V Alloy. Materials 13(13), 2998, 2020.
  • Aslantas K., Hascelik A., Çicek A., Performance Evaluation of DLC and NCD Coatings in Micro-Milling of Al7075-T6 alloy. Journal of Manufacturing Processes 81, 976-990, 2022.
  • Chae J., Park S.S., Freiheit T., Investigation of Micro-Cutting Operations. International Journal of Machine Tools and Manufacture 46, 313-332, 2006.
  • Chen Y., Wang T., Zhang G., Research on Parameter Optimization of Micro-Milling Al7075 Based on Edge-Size-Effect. Micromachines 11, 197, 2020.
  • Cheng K., Huo D., Micro-Cutting Fundamentals and Applications, Wiley Publications, First Edition, United Kingdom, 2013.
  • Cheng X., Liu J. C., Zheng G. M., et al. Study on Microcutting Fundamentals for Peripheral and end Cutting Edges in Micro-end-milling. Journal of Micromechanics Microengineering 28(1), 015011, 2018.
  • Ciecielag K., Zaleski K., Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry. Materials 15(17), 5949, 2022.
  • Dornfeld D., Min S., Takeuchi Y., Recent Advances in Mechanical Micromachining. CIRP Annals 55(2), 745- 768, 2006.
  • Erçetin A., Aslantas K., Özgün Ö., Micro-end Milling of Biomedical TZ54 Magnesium Alloy Produced Through Powder Metallurgy. Machining Science and Technology 24(6), 924-947, 2020.
  • Fabio O. C., Adriane L. M., Anna C. A., Study of The Cutting Forces on Micromilling of An Aluminum Alloy. Journal of Brazilian Society of Mechanical Science and Engineering 39, 1289-1296, 2017.
  • Gao X., Cheng X., Ling S., et. al., Research on Optimization of Micro-milling Process for Curved Thin Wall Structure. Precision Engineering 73, 296-312, 2022.
  • Gao Y. Y., Ma J. W., Jia Z. Y., et al., Tool Path Planning and Machining Deformation Compensation in High-Speed Milling for Difficult-to-Machine Material Thin-walled Parts with Curved Surface. The International Journal of Advanced Manufacturing 84, 1757-1767, 2016.
  • Hasçelik A., Aslantaş K., Mikro Tornalama İşleminde Kesici Takım Burun Yarıçapının Kesme Kuvvetlerine Etkisi. Journal of Materials and Mechatronics: A 2(1), 13-25, 2021.
  • Khandagale P., Bhakar G., Kartik V., Joshi S. S., Modelling Time-Domain Vibratory Deflection Response of Thin-Walled Cantilever Workpieces During Flank Milling. Journal of Manufacturing Processes 33, 278-290, 2018.
  • Kim C. J., Bono M., Ni J., Experimental Analysis of Chip Formation in Micro Milling. Transactions of the North American Manufacturing Research Institute of SME 30, 247-254, 2002.
  • Lazoglu I., Mamedov A., Deformation of Thin Parts in Micromilling. CIRP Annals 65, 117-120, 2016.
  • Li P. F., Liu Y., Gong Y. D., Liang L. L., Iterative Finite Element Method for Predicting Deformations of Micro Thin Wall. Journal of Northeastern University Natural Science 39, 527-531, 2018.
  • Li P., Zdebski D., Langen H. H., et al., Micromilling of Thin Ribs with High Aspect Ratios. Journal of Micromechanics and Microengineering 20(11), 115013, 2010.
  • Loehe J., Zaeh M. F., Roesch O., In-process Deformation Measurement of Thin-Walled Workpieces. Procedia CIRP 1, 546-551, 2012.
  • Ramanaiah B. V., Manikanta B., Ravi Sankar M., et al., Experimental Study of Deflection and Surface Roughness in Thin Wall Machining of Aluminum Alloy. Materials Today: Proceedings 5(2), 3745-54, 2017.
  • Shimada S., Ikawa N., Tanaka H., Ohmuri G., Uchikoshi J., Yoshinaga H., Feasibility Study on Ultimate Accuracy in Microcutting Using Molecular Dynamics Simulation. CIRP Annals 42, 91-94, 1993.
  • Sun X., Cheng K., Micro/Nano-Machining through Mechanical Cutting. Micro-Manufacturing Engineering and Technology, 24-38, 2010.
  • Warsi S. S., Jaffery S. H. I., Ahmad R., et. al., Development of Energy Consumption Map for Orthogonal Machining of Al 6061-T6 Alloy. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, 14, 2017.
  • Wu X., Liu L., Du M., et al., Experimental Study on the Minimum Undeformed Chip Thickness Based on Effective Rake Angle in Micro Milling. Micromachines 11(10), 924, 2020.
  • Xiang J., Yi J., Deformation Mechanism in Wax Supported Milling of Thin-walled Structures Based on Milling Forces Stability. CIRP Journal of Manufacturing Science and Technology 32, 356-369, 2021.
  • Yarin L., Musyak A., Hetsroni G., Fluid Flow, Heat Transfer and Boiling in Micro-Channels, Springer Berlin Heidelberg, p. 495, 2009.
  • Yi J., Wang X., Jiao L., Xiang J., Yi F., Research on Deformation Law and Mechanism for Milling Micro Thin Wall with Mixed Boundaries of Titanium Alloy in Mesoscale. Thin-Walled Structure 144, 106-329, 2019.
  • Yuan Z. J., Zhou M., Dong S., Effect of Diamond Tool Sharpness on Minimum Cutting Thickness and Cutting Surface Integrity in Ultra Precision Machining. Journal of Materials Processing Technology 62(4), 327-330, 1996.

Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method

Yıl 2023, Cilt: 4 Sayı: 1, 134 - 146, 26.06.2023
https://doi.org/10.55546/jmm.1200156

Öz

Micro-thin-walled structures are frequently encountered in micro-pumps, micro-channel cooler plates, and micro-molds in the defense, aerospace and biomedical sectors. One of the micro-machining methods frequently used to obtain micro-thin-walled structures is micro-milling. The micro-milling method makes machining possible for micro-components with high accuracy and a good surface finish. However, there are many issues to consider when micro-milling thin-walled geometries. The fact that the wall deformation is directly related to the rate of progression necessitates knowing what effects the rate of progression cause on the wall deformation. Because the micro milling technique is generally used as the final cutting process in the creation of thin wall geometries in the industry. In this study, thin-walled structures were obtained by micro-milling the Al6061-T6 material. The influence of feed rate on wall deformation was investigated by applying different feed rates in micro milling experiments. Wall deformation measurements were performed using a motorized optical profilometer device. It has been observed that increasing feed value causes an enhance in cutting forces, it also causes an increase in the deformation of the micro-thin wall. The deformation distance between the end points of the micro-milled wall geometry using a feed rate of 1 µm/tooth is three times greater than the thin-wall geometry created using a feed rate of 0.2 µm/tooth. It has been determined that the deformation is much higher in the entrance and exit areas of the micro-thin wall. The wall deformation also decreases from the upper point to the lower points of the micro-thin wall. While the deviation distance in the measurement taken from the upper point of the wall geometry obtained by using the 1 µm/tooth feed rate, where the deformation is more, can reach 100 µm, the deviation at the lower point of the wall is negligible.

Proje Numarası

Tübitak 122M223 , BAP 22.Fen.Bil.22

Kaynakça

  • Akram S., Jaffery S. H. I., Khan M., Fahad M., Mubashar A., Ali L., Numerical and Experimental Investigation of Johnson Cook Material Models for Aluminum (Al 6061-T6) Alloy Using Orthogonal Machining Approach. Advanced of Mechanical Engineering 10(9), 1-14, 2018.
  • Aslantas K., Alatrushi L. K. H., Bedir F., et. al., An Experimental Analysis of Minimum Chip Thickness in Micro-milling of Two Different Titanium Alloys. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 234(12), 1-13, 2020.
  • Aslantas K., Alatrushi L. K. H., Experimental Study on the Effect of Cutting Tool Geometry in Micro-milling of Inconel 718. Arabian Journal for Science and Engineering 46(3), 2327-2342, 2021.
  • Aslantas K., Çiçek A., The Effects of Cooling/lubrication Techniques on Cutting Performance in Micro-milling of Inconel 718 Superalloy. Procedia CIRP 77, 70-73,2018.
  • Aslantas K., Danish M., Hasçelik A., Mia M., Gupta M., Ginta T., Ijaz H., Investigations on Surface Roughness and Tool Wear Characteristics in Micro-turning of Ti-6Al-4V Alloy. Materials 13(13), 2998, 2020.
  • Aslantas K., Hascelik A., Çicek A., Performance Evaluation of DLC and NCD Coatings in Micro-Milling of Al7075-T6 alloy. Journal of Manufacturing Processes 81, 976-990, 2022.
  • Chae J., Park S.S., Freiheit T., Investigation of Micro-Cutting Operations. International Journal of Machine Tools and Manufacture 46, 313-332, 2006.
  • Chen Y., Wang T., Zhang G., Research on Parameter Optimization of Micro-Milling Al7075 Based on Edge-Size-Effect. Micromachines 11, 197, 2020.
  • Cheng K., Huo D., Micro-Cutting Fundamentals and Applications, Wiley Publications, First Edition, United Kingdom, 2013.
  • Cheng X., Liu J. C., Zheng G. M., et al. Study on Microcutting Fundamentals for Peripheral and end Cutting Edges in Micro-end-milling. Journal of Micromechanics Microengineering 28(1), 015011, 2018.
  • Ciecielag K., Zaleski K., Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry. Materials 15(17), 5949, 2022.
  • Dornfeld D., Min S., Takeuchi Y., Recent Advances in Mechanical Micromachining. CIRP Annals 55(2), 745- 768, 2006.
  • Erçetin A., Aslantas K., Özgün Ö., Micro-end Milling of Biomedical TZ54 Magnesium Alloy Produced Through Powder Metallurgy. Machining Science and Technology 24(6), 924-947, 2020.
  • Fabio O. C., Adriane L. M., Anna C. A., Study of The Cutting Forces on Micromilling of An Aluminum Alloy. Journal of Brazilian Society of Mechanical Science and Engineering 39, 1289-1296, 2017.
  • Gao X., Cheng X., Ling S., et. al., Research on Optimization of Micro-milling Process for Curved Thin Wall Structure. Precision Engineering 73, 296-312, 2022.
  • Gao Y. Y., Ma J. W., Jia Z. Y., et al., Tool Path Planning and Machining Deformation Compensation in High-Speed Milling for Difficult-to-Machine Material Thin-walled Parts with Curved Surface. The International Journal of Advanced Manufacturing 84, 1757-1767, 2016.
  • Hasçelik A., Aslantaş K., Mikro Tornalama İşleminde Kesici Takım Burun Yarıçapının Kesme Kuvvetlerine Etkisi. Journal of Materials and Mechatronics: A 2(1), 13-25, 2021.
  • Khandagale P., Bhakar G., Kartik V., Joshi S. S., Modelling Time-Domain Vibratory Deflection Response of Thin-Walled Cantilever Workpieces During Flank Milling. Journal of Manufacturing Processes 33, 278-290, 2018.
  • Kim C. J., Bono M., Ni J., Experimental Analysis of Chip Formation in Micro Milling. Transactions of the North American Manufacturing Research Institute of SME 30, 247-254, 2002.
  • Lazoglu I., Mamedov A., Deformation of Thin Parts in Micromilling. CIRP Annals 65, 117-120, 2016.
  • Li P. F., Liu Y., Gong Y. D., Liang L. L., Iterative Finite Element Method for Predicting Deformations of Micro Thin Wall. Journal of Northeastern University Natural Science 39, 527-531, 2018.
  • Li P., Zdebski D., Langen H. H., et al., Micromilling of Thin Ribs with High Aspect Ratios. Journal of Micromechanics and Microengineering 20(11), 115013, 2010.
  • Loehe J., Zaeh M. F., Roesch O., In-process Deformation Measurement of Thin-Walled Workpieces. Procedia CIRP 1, 546-551, 2012.
  • Ramanaiah B. V., Manikanta B., Ravi Sankar M., et al., Experimental Study of Deflection and Surface Roughness in Thin Wall Machining of Aluminum Alloy. Materials Today: Proceedings 5(2), 3745-54, 2017.
  • Shimada S., Ikawa N., Tanaka H., Ohmuri G., Uchikoshi J., Yoshinaga H., Feasibility Study on Ultimate Accuracy in Microcutting Using Molecular Dynamics Simulation. CIRP Annals 42, 91-94, 1993.
  • Sun X., Cheng K., Micro/Nano-Machining through Mechanical Cutting. Micro-Manufacturing Engineering and Technology, 24-38, 2010.
  • Warsi S. S., Jaffery S. H. I., Ahmad R., et. al., Development of Energy Consumption Map for Orthogonal Machining of Al 6061-T6 Alloy. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, 14, 2017.
  • Wu X., Liu L., Du M., et al., Experimental Study on the Minimum Undeformed Chip Thickness Based on Effective Rake Angle in Micro Milling. Micromachines 11(10), 924, 2020.
  • Xiang J., Yi J., Deformation Mechanism in Wax Supported Milling of Thin-walled Structures Based on Milling Forces Stability. CIRP Journal of Manufacturing Science and Technology 32, 356-369, 2021.
  • Yarin L., Musyak A., Hetsroni G., Fluid Flow, Heat Transfer and Boiling in Micro-Channels, Springer Berlin Heidelberg, p. 495, 2009.
  • Yi J., Wang X., Jiao L., Xiang J., Yi F., Research on Deformation Law and Mechanism for Milling Micro Thin Wall with Mixed Boundaries of Titanium Alloy in Mesoscale. Thin-Walled Structure 144, 106-329, 2019.
  • Yuan Z. J., Zhou M., Dong S., Effect of Diamond Tool Sharpness on Minimum Cutting Thickness and Cutting Surface Integrity in Ultra Precision Machining. Journal of Materials Processing Technology 62(4), 327-330, 1996.
Toplam 32 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Makine Mühendisliği
Bölüm Araştırma Makaleleri
Yazarlar

Ahmet Hasçelik 0000-0002-4615-0640

Kubilay Aslantas 0000-0003-4558-4516

Proje Numarası Tübitak 122M223 , BAP 22.Fen.Bil.22
Erken Görünüm Tarihi 23 Haziran 2023
Yayımlanma Tarihi 26 Haziran 2023
Gönderilme Tarihi 6 Kasım 2022
Yayımlandığı Sayı Yıl 2023 Cilt: 4 Sayı: 1

Kaynak Göster

APA Hasçelik, A., & Aslantas, K. (2023). Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method. Journal of Materials and Mechatronics: A, 4(1), 134-146. https://doi.org/10.55546/jmm.1200156
AMA Hasçelik A, Aslantas K. Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method. J. Mater. Mechat. A. Haziran 2023;4(1):134-146. doi:10.55546/jmm.1200156
Chicago Hasçelik, Ahmet, ve Kubilay Aslantas. “Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method”. Journal of Materials and Mechatronics: A 4, sy. 1 (Haziran 2023): 134-46. https://doi.org/10.55546/jmm.1200156.
EndNote Hasçelik A, Aslantas K (01 Haziran 2023) Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method. Journal of Materials and Mechatronics: A 4 1 134–146.
IEEE A. Hasçelik ve K. Aslantas, “Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method”, J. Mater. Mechat. A, c. 4, sy. 1, ss. 134–146, 2023, doi: 10.55546/jmm.1200156.
ISNAD Hasçelik, Ahmet - Aslantas, Kubilay. “Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method”. Journal of Materials and Mechatronics: A 4/1 (Haziran 2023), 134-146. https://doi.org/10.55546/jmm.1200156.
JAMA Hasçelik A, Aslantas K. Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method. J. Mater. Mechat. A. 2023;4:134–146.
MLA Hasçelik, Ahmet ve Kubilay Aslantas. “Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method”. Journal of Materials and Mechatronics: A, c. 4, sy. 1, 2023, ss. 134-46, doi:10.55546/jmm.1200156.
Vancouver Hasçelik A, Aslantas K. Examination of Deformation in Thin-Walled Structures Processed by Micro-Milling Method. J. Mater. Mechat. A. 2023;4(1):134-46.