Scopus İndeksli Yayınlar Koleksiyonu
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12573/395
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Article Citation - WoS: 5Citation - Scopus: 5Ineffectiveness 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.Article Citation - WoS: 6Citation - Scopus: 6Experimental and Statistical Damage Analysis in Milling of S2-Glass Fiber/Epoxy and Basalt Fiber/Epoxy Composites(Wiley, 2024-07-30) Sayin, Ahmed Cagri; Danisman, Sengul; Ersoy, Emin; Yilmaz, Cagatay; Kesriklioglu, SinanS2-glass fiber reinforced plastics (S2-GFRP) and basalt fiber reinforced plastics (BFRP) have emerged as crucial materials due to their exceptional mechanical properties, and milling of composite materials plays an important role in achieving desired properties. However, they have proven challenges due to relative inhomogeneity compared with metals, resulting unpredictability in quality of milling operations. The objective of this work is to investigate the effect of cutting parameters, tool geometry and tool surface materials on the surface quality of composites using burrs as a metric. S2-GFRP and BFRP composites were produced by the vacuum infusion method. Helical and straight flute end mills were manufactured from high-speed steel (HSS) and carbide rounds, and half of them were coated with titanium nitride using reactive magnetron sputtering technique. Taguchi L18 orthogonal array is used to determine the effect of tool material, tool angle, coating, cutting direction, spindle speed, and feed rate on the machining quality of S2-GFRPs and BFRPs with respect to burr formations. Milling experiments were conducted under dry conditions and then the burrs were imaged to calculate the total area and length. Statistical analysis was also performed to optimize the machining parameters and tool type for ensuring the structural integrity and performance of the final composite parts. The results showed that the selection of tool material has the most significant impact on the burr area and length of the machined surface. The novel image analysis allows to analyze the extent of the burr size with a desirable operation speed for industrial applications.