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      Investigation of deep-drilled micro-hole profiles in Hadfield steel Translated title: Untersuchung von tiefgebohrten Mikrolochprofilen in einem Hadfield-Stahl

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      1 , 2 , * , , 3
      Materials Testing
      Carl Hanser Verlag

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          Abstract

          Hadfield steel, due to its high manganese content, is difficult to drill and work-hardens very quickly. In this study, Hadfield steel material was drilled with micro-size deep holes using the electrical discharge machining (EDM) technique, and hole diameter values were examined for specific machining parameters. Experiments were carried out with three different discharge currents (6, 12 and 24 A), three different electrode rotational speeds (200, 400 and 600 rev × min −1), three different pulse durations (12, 50 and 100 µs), a fixed dielectric spray pressure (40 bars) and a fixed pulse interval (3 µs). It was determined that the hole profiles obtained following the tests are directly related to the machining parameters, and that the resulting average overcut (AOC) and taper (Tp) values increased with discharge current, electrode rotational speed and pulse duration. Analysis of variance (ANOVA) conducted demonstrates that pulse duration is the dominant parameter affecting AOC, whereas pulse duration has the highest effect on Tp. When determination coefficients and normal probability plots were compared for the mathematical models obtained from analyses conducted for the prediction of test values, it was observed that the models obtained by quadratic regression analysis exhibited a better performance than the models produced by linear regression analysis.

          Kurzfassung

          Aufgrund seines hohen Mangangehalts ist Hadfield-Stahl schwer zu bohren und verfestigt sich sehr schnell. In der diesem Beitrag zugrunde liegenden Studie wurden in einen Hadfield-Stahl tiefe Mikrolöcher mittels Funkenerosion bei verschiedenen Bearbeitungsparametern gebohrt, wobei die entsprechenden Veränderungen der Lochgeometrie untersucht wurden. Innerhalb dieses Rahmens wurden Versuche mit drei verschiedenen Entladungsstromstärken (6, 12 und 24 A), drei verschiedenen Elektrodenrotationsgeschwindigkeiten (200, 400 und 600 U × min −1), drei verschiedenen Pulsdauern (12, 50 und 100 µs), einem stabilen Sprühdruck des Dielektrikums (40 bar) und einem stabilen Pulsinterval (3 µs) durchgeführt. Es wurde festgestellt, dass die Lochprofile, die nach den Versuchen erhalten wurden, in direktem Bezug zu den Bearbeitungsparametern stehen und dass der durchschnittliche radiale Overcut (AOC) sowie der Dimensionsfehler (Tp) mit der Entladungsstromstärke, der Elektrodenrotationsgeschwindigkeit und der Pulsdauer zunahmen. Entsprechend der durchgeführten ANOVA-Analyse zeigte sich, dass die Pulsdauer der einflussreichste Parameter bezüglich des durchschnittlichen radialen Overcuts ist. Wohingegen die Pulsdauer der effektivste Parameter bezüglich des Dimensionsfehlers ist. Die mathematischen Modelle aus der quadratischen Regressionsanalyse zeigten eine bessere Performance als ein lineares Regressionsmodell bei der Vorhersage der Testwerte der Bestimmungskoeffizienten und der Normalverteilungsdiagramme der Residuen.

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          Most cited references22

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          State of the art electrical discharge machining (EDM)

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            Multi-response optimization of minimum quantity lubrication parameters using Taguchi-based grey relational analysis in turning of difficult-to-cut alloy Haynes 25

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              Taguchi design and response surface methodology based analysis of machining parameters in CNC turning under MQL

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                Author and article information

                Journal
                mp
                Materials Testing
                Carl Hanser Verlag
                0025-5300
                2195-8572
                2 March 2016
                : 58
                : 3
                : 224-230
                Affiliations
                1 Ankara
                2 Sinop
                3 Ankara, Turkey
                Author notes
                [* ] Correspondence Address, Assistant Prof. Dr. Murat Sarıkaya, Department of Mechanical Engineering, Sinop University, 57030 Sinop, Turkey. E-mail: msarikaya@ 123456sinop.edu.tr , muratsarikaya@ 123456outlook.com

                Dr. Volkan Yılmaz, born in 1983, studied at the Kazan Vocational High School at Gazi University, Ankara, Turkey, and received his PhD from the Department of Mechanical Education, Gazi University, in 2013. His research areas include CAD/CAM technology, manufacturing technology, optimization, modeling, design, conventional and alternative cutting applications.

                Assist. Prof. Dr. Murat Sarıkaya, born in 1984, is a lecturer in the Department of Mechanical Engineering, Faculty of Engineering and Architecture, Sinop University, in Sinop, Turkey. He received his PhD degree from the Department of Mechanical Education, Gazi University, Ankara, Turkey in 2014. His areas of interest include manufacturing technologies, machinability of materials, design of experiments, optimization and modeling.

                Assoc. Prof. Dr. Hakan Dilipak, born in 1971, is Associate Professor at University of Gazi in Ankara, Turkey. He received his PhD degree from the Department of Mechanical Education of Gazi University in 2001. His areas of interest include CNC, CAD/CAM, machinability of materials, sheet metal molding, casting, process planning and computer-aided programming.

                Article
                MP110846
                10.3139/120.110846
                568ce1c8-4cca-49ab-a05b-a05c10c2fb20
                © 2016, Carl Hanser Verlag, München
                History
                Page count
                References: 25, Pages: 7
                Categories
                Fachbeiträge/Technical Contributions

                Materials technology,Materials characterization,Materials science
                Materials technology, Materials characterization, Materials science

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