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- MakaleYalnız künye2026Scopus SJRQ2Investigation of the effect of ultrasonic assisted milling and minimum quantity lubrication methods on the machinability of Hardox 500 steel
Dalgıç, Aras; Mahmat, Aybars
Hardox steel is widely used in agriculture, mining and transportation due to its mechanical properties such as high wear resistance, high impact resistance, high hardness, high durability and long life. The machinability of Hardox 500 is difficult as its high hardness and wear resistance lead to tool wear and low machining speed. Recently, various processing and cooling methods have been developed to increase machinability. Ultrasonic assisted milling (UAM), one of these methods, is a method used as an alternative to conventional milling (CM) in the milling of traditionally difficult-to-machine materials. In addition, minimum quantity lubrication (MQL) is a cooling method used to provide lubrication and cooling in the cutting area. In this study, the impacts of machining method, feed rate and spindle speed on cutting force, surface roughness and tool wear in milling of Hardox 500 steel were investigated. In the MQL method, mixtures with nano-sized SiC particles were obtained and applied to the cutting area. In the study, MQL reduced cutting forces by up to 19 %, surface roughness by 18 %, and tool wear by 30 % compared to dry machining, while UAM further decreased cutting forces by 17 %, surface roughness by 15 %, and tool wear by 12 % compared to CM. These results demonstrate that MQL and UAM significantly enhance machining performance over conventional and dry methods.
- MakaleAçık Erişim2025Scopus SJRQ2Ultrasonic-assisted high-speed micro-milling of Ti6Al4V
Mahmat, Aybars; Agar, Salih; Tosun, Nihat
In this study, the effects of different cooling techniques and process parameters on the performance characteristics of ultrasonic and conventional micro-milling (1-micron fixed amplitude, 20 and 30 kHz frequencies) of Ti6Al4V alloy were experimentally investigated. The impact of independent factors on tool life, cutting force, surface topography, surface roughness and cutting temperature was determined in order to find out machinability characteristics in this paper. Machining operations were performed under 20,000, 40,000 and 60,000 rpm revolution speed. The cutting depth and feed rate of the machining were kept fixed at 0.02 mm and 0.66 mm/s, respectively. Uncoated carbide and TiSiN-coated carbide cutting tools were used in machining operations. Dry machining and two different minimum quantity of lubrication (MQL) methods were used as cooling methods. According to the results achieved in the existing study, the ultrasonic micro-milling improved the surface roughness, reduced cutting forces, cutting zone temperature, and cutting tool wear. It was also found that MQL methods among other methods used in the present study have a greater effect on performance characteristics. As the spindle speed increased, the workpiece surface roughness, cutting force and tool life decreased, while the cutting zone temperature increased.
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