Effect of cutting tool geometry on cutting performance and hole quality

Machining has an important place in the growing industry that has left behind the days of never and innovation. The building block of machining is the consumer team and the day in the raw material industry is entrepreneurial. There is a need for waste to reduce newly designed consumptions and limit their performance. As a result of combining the raw materials in various proportions, the desired values and performance values are given. As a result of technological developments, one of the most important restrictions that many material types have by their companies is the questioning of their machinability in the field of machining. Brass is the general name of yellow alloys obtained by adding zinc to copper in certain proportions. Brass has become the first choice material in the electrical equipment and precision engineering industry that requires precision due to its long life and affordability, its unique physical properties that cannot be compared with other materials. High strength brasses" are available for applications that require higher strength. These contain additional alloying elements that further improve properties, such as manganese. Some high strength brasses achieve strengths comparable to steels. These alloys contain the base metal copper, ranging from 58% to 95%. The remaining metals are usually zinc and lead, which is below 4%. In the softened or annealed state, brasses are ductile and strong, but when they are hardened by cold working processes such as rolling or drawing, their strength increases significantly. Strong, rigid structures can be joined from extruded and extruded sections. Rods and rolled sheet and sheet metal can be manufactured into containers and other items of equipment operating under pressure. The strength of brasses is largely maintained at temperatures up to about 200 ºC, and at 300 ºC it decreases by about 30%; This is a positive situation compared to many alternative materials and easily exceeds the properties of plastics. Brasses are well suited for use at cryogenic temperatures, since their properties, especially strength and toughness, are maintained or slightly improved under such conditions. Brasses can be easily joined to other copper alloys or other metals with most commercial joining processes such as riveting, soft soldering, hard soldering with silver, and friction welding. Adhesive bonding application can also be used. With its unique combination of properties, brass is the best material to manufacture many parts. This reduces the production cost and brings savings. For example, properties such as good strength and ductility, excellent corrosion resistance and superior machinability can be combined. Brass sets the standard in the evaluation of the machinability of other materials. In addition, rice can be available in a wide variety of product forms and sizes to require minimal processing. In this regard, the design and production of cutting tool geometries in accordance with the raw material directly affects the machinability, surface quality and machining costs of the raw material to be processed. In this study, radial rake angle, axial rake angle, rolling radius and helix angle parameters of the cutting tools were determined and optimized using the taguchi method, as a result of technological developments, CW511L brass material is used in many sectors and is a frequently preferred raw material in the field of machining. has been done. The final cutting tool was created with optimized parameters and surfaceroughness, feed forces, chip weight, burr height were investigated. Within the scope of the thesis study, 28 CW511L(CuZn38As) low lead brass alloy materials with Ø90 x 30 mm dimensions were used. Fanuc ROBODRILL Alpha D21LiB5 CNC vertical machining center was used in all machining experiments. Solid carbide tools required for machinability tests of CW511L lead free brass alloy were produced on ANCA FX7 Linear machine sharpening machine. The design of the cutting tools was made in the ANCA Toolroom program. To be used in machining experiments of CW511L lead free brass alloy; 27 tools were produced in different geometries with 4, 8 and 12 ° radial rake angle, rake angle and 0, 5 and 10 ° helix angle, 10, 20 and 30 2, 0 and 2 ° axial micron rolling radius. Within the scope of the thesis study, according to the results obtained from the taguchi experiments, the set was produced again and validation experiments were carried out. The cutting forces were measured using a Kistler 9129AA type multi dynamometer, which can operate under water at a temperature range of 0 component 70 °C, with a maximum measurement of 10 kN during drilling operations. The force data obtained were transferred to the computer using the LabAmp system Type 5167A amplifier. Data analyzed using Dynoware software After all the drilling processes, the surface roughness values of the inner diameter surfaces were measured and the surface qualities were compared. Mitutoyo Surftest Extreme SV 3000 CNC surface roughness and form measuring device was used for surface roughness measurements. "Arithmetic Average Roughness", Ra, and "Maximum Roughness Depth", Rz, values of the sample surfaces were measured. The helix angle in the cutting tool geometry affects the improvement of the cutting feature of the cutting tool, the removal of the chip from the part more easily, and the parameters given to the machined time. The radial rake angle is the cutting angle in the groove of the cutting tool. This angle shows importance according to the machinability parameter of the raw material. The radial rake angle can also be expressed as the cutting angle. Axial rake angle is the angle expressed as the discharge angle, which is made to prevent friction in the cutting process when the cutting too l is in a fixed position while the cutting tool is rotating or the raw material is rotating. The value of the angle is determined by the nature of the raw material. The rolling radius is subjected to axial and radial forces during cutting tool operation. It is the process to prevent this and to ensure that more raw materials are processed.