Experimental comparison of flow peening GOV and abrasive flow machining AFM processes on Ti-6Al-4V aerospace material

Yıl 2024, Cilt: 39 Sayı: 4, 2271 - 2288, 20.05.2024

Kürşad Göv Murat Kalak

https://doi.org/10.17341/gazimmfd.1261067

Öz

Ti-6Al-4V finds place from aerospace applications to medical industry due to its superior mechanical features such as high strength, low density, high temperature strength and excellent corrosion resistance. Despite its wide usage applications such as aircraft turbine blades, aircraft structural components and rocket engines, it is a difficult material to machine, manufacture and surface treatment with traditional methods. Non-traditional finishing and surface treatment methods namely abrasive flow machining (AFM) and shot peening processes are applied to obtain desired surface quality for Ti-6Al-4V and difficult to cut materials. The newly developed flow peening (GOV) process, which has the surface finishing capability of the AFM and the compressive residual stress generation capability of the shot peening process together, has been experimentally compared in Ti-6Al-4V workpieces pre-prepared by wire electric discharge cutting machine. The effects of GOV and AFM process parameters on material surfaces were investigated to evaluate the surface roughness, surface quality, material removal amount and white layer thickness. The best surface roughness value, Ra was obtained 0.92 um and the highest amount of chip removed from the surface was 3.6 mg by GOV process while these values were 0.53 um and 1989.15 mg by AFM. While the GOV process improves the surface quality by removing less amount of chip, the AFM process reaches approximate surface quality by removing excess chip.

Anahtar Kelimeler

GOV process, abrasive flow machining (AFM), aerospace material (Ti-6Al-4V), white layer, surface roughness (Ra)

Akışla dövme GOV ve aşındırıcı macunla işleme AMİ proseslerinin Ti-6Al-4V havacılık malzemesinde deneysel kıyaslanması

Öz

Ti-6Al-4V malzemesi sahip olduğu yüksek mukavemet, düşük yoğunluk, yüksek sıcaklık mukavemeti ve mükemmel korozyon direnci gibi özelliklerinden dolayı havacılık ve uzay sektöründen medikal sektörüne kadar nitelikli alanlarda yaygın kullanılmaktadır. Uçak türbin kanatçığı, uçak yapısal bileşenleri ve roket motoru gibi geniş kullanım alanına rağmen işlenmesi, üretilmesi ve yüzey iyileştirmesi geleneksel yöntemler ile zor bir malzemedir. Bu ve benzeri işlenmesi zor malzemelerin istenilen yüzey kalitesini elde etmek için aşındırıcı macunla işleme (AMİ) ve bilyeli dövme işlemleri gibi geleneksel olmayan yüzey işleme yöntemleri kullanılmaktadır. AMİ prosesinin yüzey bitirme ve bilyeli dövme işleminin basma yönünde artık gerilme oluşturma kabiliyetlerinin birleştirilmesi ile yeni geliştirilen akışla dövme (GOV) prosesi, elektriksel tel erozyonla kesilerek hazırlanmış Ti-6Al-4V malzemesinde deneysel kıyaslamalı çalışılmıştır. Yüzey pürüzlülüğü, yüzey kalitesi, malzeme kaldırma miktarı ve beyaz katman tabakasının kalınlığını değerlendirmek için GOV ve AMİ işlem parametrelerinin, malzeme yüzeyi üzerindeki etkileri incelenmiştir. GOV prosesinde en iyi yüzey pürüzlülüğü Ra 0,92 um ve malzeme kaldırıma miktarı 3,6 mg olarak, AMİ işleminde ise bu değerler Ra = 0,53 um ve 1989,15 mg olarak elde edilmiştir. GOV işlemi, daha az talaş kaldırarak yüzey kalitesini iyileştirirken, AMİ işlemi çok daha fazla talaş kaldırarak yaklaşık yüzey kalitesine ulaşmaktadır.

Anahtar Kelimeler

GOV proses, aşındırıcı macun ile işleme (AMİ), havacılık malzemesi (Ti-6Al-4V), beyaz katman, yüzey pürüzlülüğü (Ra)

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