Akademik Veri Yönetim Sistemi
International Conference on Engineering Technologies (ICENTE’23), Konya, Türkiye, 23 - 25 Kasım 2023, ss.205-210
In machining operations, continuous chip formation has been a problem affecting the surface quality of machined parts, tool-life, cutting fluid performance and energy dissipation. Although the methods such as cutting parameter optimization, high-pressure coolants, chip breakers, chip-pullers, and modulation assisted machining (MAM) with piezo actuators has been used in the previous studies and practices, the problem still exist or requires expensive equipment. This study focuses on MAM which is quite complex, but effective method in chip management. The sinusoidal cutting path of the MAM was replicated by modulating the tool in the feed direction by computer numerical control (CNC) manipulation without using an expensive and/or complex system. A program was written in Matlab to create the G-codes based on MAM parameters so that the cutting tool completely disengages from the workpiece during each turning cycle, and it results in the disruption of the severe and continuous tool chip contact. This method enables the control of the chip sizes cost effectively without any external devices such as piezoelectric transducers and high-resolution sensors. To test the effectiveness of the method, cutting experiments were conducted under two different turning speeds with various MAM parameters on Al6061-T6 alloy. The results of the experiment indicate that while the cutting insert with chip brakers still creates continuous chips in the CNC turning operations of a ductile workpiece material, this method can be effectively used for controlling the chip length at different cutting and modulation frequencies.