Friction drilling processes are used commonly in hot forming operations. This process is similar to drilling processes but without using chip. This process is used especially for joining thin-walled metal components. In this study, the drilling process using centerdrill is investigated both experimentally and numerically. The finite element analyses (FEA) were conducted using deform-3D software based on finite element method (FEM). In this study, an analytic model is developed, which calculate the process parameters as torque and axial power, heat transfer coefficient. A comparison was also made for temperature, torque and axial force obtained from experimental and numerical analyses. At the end of the study, while the torque and axial force values decrease with increasing of spindle speed, temperature values of centerdrill and workpiece increase with increasing of spindle speed. A good consistency between both experimental and FEA simulations was found during the centerdrill process.
Abstract. In this study, the drilling process was performed with Kirschner wire (K-wire) for stabilization after reduction of Salter–Harris (SH) type-3 epiphyseal fractures of distal femur. The study was investigated both experimentally and numerically. The numerical analyses were performed with finite element method (FEM), using DEFORM-3D software. Some conditions such as friction, material model and load and boundary must be identified exactly while using FEM. At the same time, an analytic model and software were developed, which calculate the process parameters such as drilling power and thrust power, heat transfer coefficients and friction coefficient between tool–chip interface in order to identify the temperature distributions occurring in the K-wire and bone model (Keklikoǧlu Plastik San.) material during the drilling process. Experimental results and analysis results have been found as consistent with each other. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 80° N, 120° N, 69 °C and 61 °C for 400 rpm in experimental studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 65° N, 87° N, 91 °C and 82 °C for 800 rpm in experimental studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 85° N, 127° N, 72 °C and 67 °C for 400 rpm in analysis studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 69° N, 98° N, 83 °C and 76 °C for 800 rpm in analysis studies. A good consistency was obtained between experimental results and finite element analysis (FEA) results. This proved the validity of the software and finite element model. Thus, this model can be used reliably in such drilling processes.
This study experimentally investigated the effects of machining parameters on the built-up-layer (BUL) and built-up-edge (BUE) formation and the wear behavior of cutting tools during the machining of the AISI 310 austenitic stainless steel with titanium-carbide cutting tools. Five different cutting speeds (50, 75, 100, 125 and 150) m/min, three feed rates (0.15, 0.20 and 0.25) mm/r and two cutting depths (1.5, 2) mm were used as the cutting parameters. The highest accumulation of the BUL and the BUE was observed at a cutting speed of 50 m/min, a feed rate of 0.15 mm/r and a cutting depth of 1.5 mm. Keywords: built-up edge, built-up layer, machining, stainless steels Ta {tudija eksperimentalno preu~uje vpliv parametrov rezanja na nakopi~eno plast (BUL) in nakopi~en rob (BUE) ter na vedenje orodja za odrezovanje med stru`enjem AISI 310 avstenitnega nerjavnega jekla z orodjem iz titanovega karbida. Kot parametri odrezovanja je bilo uporabljeno pet razli~nih hitrosti (50, 75, 100, 125 in 150) m/min, tri hitrosti podajanja (0,15, 0,20 in 0,25) mm/r in dve globini rezanja 1,5 mm in 2 mm. Najve~ja akumulacija BUL in BUE je bila opa`ena pri hitrosti rezanja 50 m/min, hitrosti podajanja 0,15 mm/r in globini rezanja 1,5 mm.
The determination of the cutting-parameter values that cause increases in vibration values is important to minimize the errors that can occur. Thus, the first aim of this study was to investigate the optimum cutting-parameter values and tool-path strategies in ball-end milling of the EN X40CrMoV5-1 tool steel with three coated cutters using the Taguchi method. The parameters taken into consideration are the cutting speed, feed rate, step over and tool-path strategies. The second aim of the study, a model for the tool acceleration as a function of the cutting parameters, was obtained using the response-surface methodology (RSM). As a result, the most effective parameter within the selected cutting parameters and cutting strategies for both inclined surfaces and different coatings was the step over. In terms of tool coatings, the most deteriorating coating for the tool acceleration on both inclined surfaces was the TiC coating. In addition, the response-surface methodology is employed to predict the tool-vibration values depending on the cutting parameters and tool-path strategy. The model generated gives highly accurate results. Keywords: inclined surfaces, ball-end milling, tool acceleration, Taguchi method, response-surface methodology, response optimization Neoptimalni rezalni parametri med mehansko obdelavo lahko povzro~ijo ne`elene vibracije in posledi~no napake. Prvi cilj avtorjev te {tudije je bil dolo~iti optimalne vrednosti rezalnih parametrov in strategije potovanja orodja med mehansko obdelavo orodnega jekla EN X40CrMoV5-1 s krogli~nim frezalom s tremi rezili z razli~no prevleko (TiC, TiN in TiAlN). Za to so uporabili Taguchi-jevo metodo. Parametri, ki so jih avtorji zajeli v {tudiji so bili: hitrost rezanja, velikost odvzema, korak odvzema (preskok) in strategija poti orodja. Drugi cilj avtorjev te {tudije je bil izdelati model pospe{evanja orodja v odvisnosti od rezalnih parametrov, z uporabo metodologije odziva povr{ine (angl. RSM). Ugotovili so, da je korak odvzema (angl.: step over) naju~inkovitej{i parameter med izbranimi rezalnimi parametri in rezalnimi strategijami, tako za oba izbrana nagiba (ukrivljenosti) povr{ine, kot tudi izbrane trde prevleke. Med izbranimi trdimi prevlekami se je v vseh pogojih frezanja kot najslab{a izkazala TiC prevleka. RSM metodologija dodatno omogo~a napoved vibracij orodja v odvisnosti od rezalnih parametrov in izbrane strategije poti orodja. Izdelani model daje zelo to~ne rezultate. Klju~ne besede: nagib (ukrivljenost) povr{ine, mehanska obdelava s krogli~nim frezalom, pospe{ek orodja, Taguchi metoda, metodologija odgovora povr{ine, optimizacija odgovora
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