Determination of cutting parameters and investigation of effect on production costs in turning machine gearbox cover

Gearbox; The gear group is the gear group that provides the desired torque value to the shaft or differential. On the gearbox cover, machine parts and gray cast iron material, which are widely used in the automotive industry, are preferred. Gray cast iron is the most widely used cast iron type and it is used by taking preheating and cooling after welding. In gray cast iron, water can be supplied and tempered with similar heat treatment applied to steel. The main advantages are better workability, higher wear resistance and strength, better dimensional stability. In this thesis, the cutting parameters of DDL-25 gray cast iron material on computer controlled lathe machine have been tested. In the study, PVM coated (Ti, Al) N + TiN cutter with 0.8 mm geometry has been used at the fixed chip depth VCMT160408 tip radius. Experiments have been performed by changing the cutting speed parameters (200 m / min - 450 m / min - 700 m / min) and the feedrate parameters (0.08 mm / rev - 0.15 mm / rev - 0.20 mm / rev). As a result of the experiments, it has been observed that the surface quality improvement with the increase in the cutting speed and the deterioration in the surface with the increase in the rate of progress. The operations of DDL-25 gray cast iron (hardness 180-250 HB, min tensile strength 250 N / mm²) used in the transmission of construction machinery have been investigated. The VCMT160408 cutting tool has been used with a 32-inch turning tool. If the production time and production cost are prioritized, the cutting speed and cutting speed should be above the existing conditions and the cutting speed of 450 m / min and the 0,15 mm / rev feed rates have been found to be suitable. At the same time, due to the increase in feed rate, the increase in the micro-level in the surface roughness should be considered. 9 pieces are produced per day and 9 hours daily working conditions. In the fifth case, 11 pieces will be produced per day. 300 pieces of gearboxes that are intended to be produced can be finished in 33 days with the production of 9 pieces per day. In the 5th case, it will be possible to produce 11 pieces per day and be completed in 28 days. 1 day labor and machine cost is 1,575,00 TL, so 5 days labor and machine cost savings is 8.225,00 TL.