Application of ball material method to Al6061 material with new type insert insert and its properties surface investigation

Deep rolling is a widely used surface treatment method for improving material surfaces. With this method, the mechanical properties (hardening, wear resistance, fatigue) and surface roughness of the material surface are improved. The aim of this study is to investigate the usability of Al6061-T6 material with different turning processes (longitudinal, conical, radius) by deep rolling and to experimentally examine the results of deep rolling with a newly designed insert that can be fixed to used tool holders. In the study, based on the WNMG insert tip model, a spherical tip insert type was manufactured, different parameters were used and deep rolling process was applied to Al6061-T6 material. Deep rolling processes were performed on a CNC lathe and the process parameters were 143N, 330N, 495N rolling force, 0.04 mm/rev, 0.08 mm/rev and 0.12 mm/rev with feed rate of 400 rpm, 600 rpm and 800 rpm. spindle speeds has been determined. Surface roughness of turned Al6061-T6 parts were investigated and the effects of parameters on surface roughness were analyzed. At the end of the study, it was seen that the insert tip designed in accordance with the used turning tool holders can be used in deep rolling, and it improves the surface roughness in deep rolling of turning parts with different turning contours. As a result of microhardness, the most ideal parameters were determined on Ra. Surface images were taken under the optical microscope and it was observed that the surface deformations occurred with the increase of the advancement. The presence of fıne-grained layers can be mentioned in SEM images. In EDX analysis, it was observed that the maximum change on the surface occurred at the rate of %C.