Scopus İndeksli Yayınlar Koleksiyonu
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12573/395
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Article Surface Integrity and Tool Wear in S2-GFRP Milling: Experimental and Statistical Evaluation of Cutting Parameters and DLC and TiAlN Tool Coatings(Springer London Ltd, 2026) Danisman, Sengul; Yilmaz, Cagatay; Ersoy, Emin; Kesriklioglu, SinanIn this study, the surface integrity of S2-glass fiber-reinforced polymer (S2-GFRP) composites during milling with carbide cutters was investigated using a two-phase experimental design, focusing on surface roughness (Ra), burr area, and tool wear (VB). In the first phase, using a Taguchi L9 design, the effects of coating type (uncoated, TiAlN, DLC), spindle speed (2000-6000 rpm), and feed rate (0,15-0,25 mm/rev) on Ra and burr area were evaluated. In this short machining range where tool wear was negligible, the optimal combination yielding the lowest Ra (approximate to 0.97 mu m) and the minimum burr area (approximate to 231 mm & sup2;) was determined to be 4000 rpm, 0,15 mm/rev, and the DLC-coated tool. Regarding the effect of tool material on Ra, the DLC-coated tool provided approximately 4 and 2 times better results than the uncoated and TiAlN-coated tools, respectively. In the second phase, experiments extended up to 130 passes with this optimal parameter set showed that Ra increased significantly with increasing VB, and the burr area exhibited threshold-like behavior. In particular, a sudden increase in Ra and the burr area was observed when the VB approximate to threshold of approximately 100 mu m was exceeded; partial regression analyses confirmed different burr-formation tendencies in the low- and high-wear regimes. The results reveal that DLC coating initially provides superior performance in S2-GFRP milling, but surface degradation accelerates after the critical VB threshold.Article Citation - WoS: 5Citation - Scopus: 6Ineffectiveness of Flood Cooling in Reducing Cutting Temperatures During Continuous Machining(Springer London Ltd, 2022-09-19) Kesriklioglu, SinanWater-based metalworking fluids are applied in the form of a liquid jet to flood the entire cutting zone and increase the tool life. The objective of this study is to investigate the effectiveness of flood cooling in reducing the tool chip interface temperatures during continuous cutting. An instrumented smart cutting tool with a thin film temperature sensor was fabricated to accurately measure the real-time cutting temperatures from 1.3 mu m below the tool chip interface in orthogonal turning of AISI 4140 steel under dry and flood cooling conditions. The cutting process was simulated in Deform 2D with the Johnson-Cook material model to present the transient temperature distributions on the coated cutting insert. The heat flux into the cutting tool was also estimated analytically and then three-dimensional finite element heat transfer simulations were performed to determine the maximum convective heat transfer of the cutting fluid in steady state. The measurements with the embedded thermocouple showed that flood cooling with a water-based cutting fluid slightly lowers the tool chip interface temperature. Moreover, the chip color may not be a good characteristic indicator to evaluate the cutting temperature in machining of metals. It was also found that flood cooling becomes more effective at a distance of approximately 150 mu m from the cutting edge where the chip does not contact the rake face of the cutting tool.