Experımental And Numerıcal Investıgatıon Of The Machınabılıty Of Gray Cast Iron Materıals

Thesis Type: Postgraduate

Institution Of The Thesis: Turkey

Approval Date: 2018

Thesis Language: Turkish

Student: Burak Özcan

Supervisor: ADNAN AKKURT


In this study, GG30 gray cast iron and GGG50 spherical graphite cast iron were subjected to turning tests at four different cutting speeds (400, 450, 500, 560), at three different feed rates (0,40 0,50 0,63) under dry cutting environment using silicon nitride ceramic inserts having with two different tool geometry. Cutting forces, surface roughness and tool wear measurements were performed during machining experiments. Two dimensional (orthogonal) and three dimensional cutting simulations were carried out by utilizing the Lagrangian finite element model using the commercially available finite element software Advantedge according to the determined test parameters. The experimental measurements and finite element model results were compared and validated. Two-dimensional (orthogonal) chip removal simulations were conducted using Jhonson-Cook (JC) material model and the library of Advantedge material model. Then, the Advantedge material model results and JC material models taken from the literature were compared. The cutting forces and the temperature distribution values between the tool and the workpiece during turning process were investigated using the simulations results. The simulation results showed that the cutting forces, the temperature distributions, the stress and strain results during the machining of cast irons were within acceptable limits. The same characteristic trend was observed between the results of Advantedge material model and JC material model taken from the literature. However, it was seen that the Advantedge material model and JC material model exhibited the different behavior in terms of size of the output values. Analysis of variance (ANOVA) was also employed to determine the influence of the cutting parameters on the surface roughness, cutting forces and tool wear.