Kokil Kalıba Döküm Yöntemi ile Üretilmiş Al-12Si-(0,02-1)Sr Alaşımlarının CVD-TiCN/Al2O3/TiN Kaplamalı Kesici Uç ile Tornada İşlenmesinde Kesme Kuvveti ve Yüzey Pürüzlülüğü Üzerine Deneysel Çalışma

Bu çalışmada, farklı oranlarda (%0,02; 0,1 ve 1) stronsiyum (Sr) içeren üç adet Al-12Si-Sr alaşımı kokil kalıba döküm yöntemiyle üretildi. Üretilen alaşımların içyapıları standart metalografik yöntemlerle, sertlik ve çekme dayanımı değerleri ise sırasıyla Brinell ölçüm yöntemi ve çekme deneyi ile belirlendi. Farklı Sr oranları ve kesme parametrelerinin bu alaşımların tornada işlenmesi esnasındaki kesme kuvveti ve yüzey pürüzlülüğü üzerindeki etkileri, farklı kesme hızı (200, 300 ve 400 m/dak), ilerleme (0,05; 0,1 ve 0,15 mm/dev) ve sabit kesme derinliği (1,5 mm) koşullarında CVD-TiCN/Al2O3/TiN kaplamalı karbür kesici uç kullanılarak araştırılmıştır. Metalografik incelemeler, Al-12Si-0,02Sr alaşımının içyapısının α, ötektik alüminyumsilisyum, Al-Fe-Si (δ) fazları ile primer silisyum parçacıklarından, Al-12Si-0,1Sr alaşımının içyapısının ise Al-12Si-0,02Sr alaşımında gözlenen fazlara ilave olarak Al-Sr-Si fazından oluştuğunu göstermiştir. Bu incelemelerde ayrıca Sr oranı arttıkça Al-Sr-Si fazının büyüdüğü ve/veya bu faz parçacıklarının sayısının arttığı gözlenmiştir. Üretilen alaşımlar içerisinde en yüksek sertlik ve çekme dayanımı değeri Al-12Si-0,1Sr alaşımından elde edilmiştir. Alaşımların kopma uzaması değeri ise artan Sr oranı ile sürekli azalmıştır. İşleme testlerinde kesme hızının artması ile kesme kuvveti ve yüzey pürüzlülüğünün azaldığı, ilerlemenin artması durumunda ise bu değerlerin de arttığı tespit edilmiştir. Tornalama testlerinde en düşük kesme kuvveti ve yüzey pürüzlülüğü değerleri, Al-12Si-0,1Sr alaşımının işlenmesinde ölçülürken, en yüksek değerler ise Al12Si-0,02Sr alaşımında ölçülmüştür. Alaşımların tornalanması esnasında yığıntı talaş (YT) oluşumu gözlenmiştir. YT oluşumunun yüksek kesme hızı ve düşük ilerleme kombinasyonları kullanılarak azaltılabileceği ortaya konulmuştur. Kesici uçta en az YT oluşumu, Al-12Si-0,1Sr alaşımında gözlenirken, en fazla YT oluşumu ise Al-12Si-0,02Sr alaşımında gözlenmiştir. İşleme deneylerinden elde edilen bulgular, alaşımların yapısal ve mekanik özelliklerine dayandırılarak irdelenmiştir.

Experimental Study on Cutting Force and Surface Roughness in Turning with CVD-TiCN/Al2O3/TiN Coated Cutting Insert of Al-12Si-(0.02-1)Sr Alloys Manufactured by Permanent Mold Casting Method

In this study, three Al-12Si-Sr alloys containing different ratios (0.02; 0.1 and 1%) strontium (Sr) were manufactured by the permanent mold casting method. The microstructures of the manufactured alloys were determined by standard metallographic methods, and the hardness and tensile strength values were stated by the Brinell method and tensile test, respectively. The effects of different Sr ratios and cutting parameters on the cutting force and surface roughness during turning of these alloys were investigated using CVDTiCN/Al2O3/TiN coated carbide inserts under the different cutting speeds (200, 300 and 400 m/min), feed rate (0.05; 0.1 and 0.15 mm/rev) and constant depth of cut (1.5 mm) conditions. Metallographic examinations revealed that the microstructure of the Al-12Si-0.02Sr alloy consists of α, eutectic aluminum-silicon, Al-FeSi (δ) phases and primary silicon particles, while the Al-12Si-0.1Sr contains Al-Sr-Si phase in addition to the phases observed in the Al-12Si-0.02Sr alloy. In these investigations, it was also observed that as the Sr ratio increased, the Al-Sr-Si phase grew and/or the number of these phase particles increased. The highest hardness and tensile strength values were obtained from Al-12Si-0.1Sr alloy among the produced alloys. The elongation to fracture value of the alloys decreased continuously with increasing of Sr ratio. It was seen that the cutting force and surface roughness decreased with the increase of cutting speed, whereas increased with the increase of feed rate in the machining tests. The lowest cutting force and surface roughness values were measured in the machining of Al-12Si-0.1Sr alloy, while the highest values were measured in Al-12Si-0.02Sr alloy in turning tests. Built-up edge (BUE) formation was observed during the turning of the alloys. It was revealed that BUE formation could be reduced by using a combination of high cutting speed and low feed rate. While the least BUE formation was observed in the Al-12Si-0.1Sr alloy at the cutting tool rake face, the highest BUE formation was observed in the Al-12Si-0.02Sr alloy. The findings obtained from the turning tests were discussed in based on the structural and mechanical properties of the alloys.

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