A Study on the Development ® of Aluminum Alloys Using Ss the Mechanical Surface Improvement Method Using the Taguchi Method Suleyman Cinar Cagan, Bellam Venkatesh and Berat Baris Buldum Abstract The surface quality of the manufactured parts is an important factoraffect- ing the functional properties such as corresion resistanoz and fuligue strength of the part, For this reason, this study aims to develop surface roughness of Al 7075-T6 material which is generally used in the aviation and aerospace industry. In order to enhance the surface quality of the parts, the ball burnishing apparatus was designed and experiments were carried out at different parameters (force, feed rate, and medium). The design of the experiments was carried out using the Taguchi method, and the Ly orthogonal array was chosen. Also, the contributions of the parameters on surface roughness have been calculated with an analysis of variance (ANOVA). Consequently, the optimum surface roughness value was reached with parameters of the force 200 N. mineral ail, and feed ruiz of 0.1 aun/min. The most important parameters affecting the surface quality are found to be the bumishing force, feed rate, and medium, respectively. Keywords Mechanical surface improvement » Aluminum alloy + Taguchi method » Ball burnishing, 1 Introduction Aluminum and its alloys have become incseasingly industrialized due to their lightweight as well as their strength and casy forming ability [1-3]. Aluminum alloys play a significant role in the development of space, aviation, weapons, and defense 8... Cugun (pg) - BB, Beldum Mechanical Engincering Department, Engineering Faculty, Mersin University, Cifiiieay: Campus, 33343 Yenisehir, Mersin, Tuskey e-mail: cinarcaygan @mersin.cdu $e BB Aukiem ‘e-mail: bacisbuldumn? mcminedu tr 1B. Verikalesh Mechanical Enginccring, CMR Institute of Technology, Hyderabad, India e-mail: bvenkaicshO9S@gmatl.com © Springer Nature Singapore Puc 1d, 2020 315 L. Vijayaraghavan ov ab. (eds.), Emerging Trends ix Mechanical Engineering. Loctare Notcs in Mechanical Lngineering, bps: ded oqu/ 10. 100797. 981 -32-99531-8 31316 S.C. Cagan etal. industry due to their mechanical properties us well as their lightweight (density is 2.81 gfem?), Within these alloys, the importance and application areas of 7075-T6 grade aluminum alloys are increasing especially inthe defense and aerospace indus- try 12, 31: Surface roughness is important in determining the quality of the product to be oblained as it affects the mechanical properties. performance, and cost of production of the mechanical pants [4, 5]. Characteristic irregularities oocur on the surface of the workpiece after many machining processes [6]. Ball bumishing process is an elementary. quick, and inexpensive finishing process used to remove these irregu- larities [7, 8]. The finishing process is @ recognized mechanical surface treatment method for imparting certain physical, mechanical, and tribological properties to the workpiace [9]. In this process, the surface of the workpiece is compressed by applying an apparatus in order to obtain a smooth surface by removing irregularities lin: the surface by plastic deformation [9, 10]. Asa result, this process can substitute for other conventional surface treatment techniques such as turning, milling, honing, and grinding The parameters affecting surface quality when applying to finish to the work- piece are workpiece materials, ball materials, ball types, burnishing forces, number of passes, ball sizes, lubricants, feed mates, and burnishing speed. When the literature is searchad, it is seen that researchers are studying different material and burnish- ing process parameters (force, speed, etc.) [8, 10-17]. There is no study about the application of ball burnishing under different medium conditions ia the literature. In this experimental study. the optimum surface roughness value of the aluminum alloy was investigated using three different burnishing forces, three different feed ratws, and three different burnishing medium. Also, the experimental design was planned by selecting Ly orthogonal Taguchi method. 2 Materials and Methods 24° Material and Experiments ‘The experiments were carried out using Al 7075-16 aluminum bar. This workpiece material's sizes were O50 x 280:mm. The chemical content of the Al 7075-T6 used as the workpiece is indicuted in Table |. This workpiece is divided into 9 equal parts Different parameters have been applied to each pant. The experiments were carried oat on a conventional lathe as shown in Fig. | The Al 7075-T6 workpiece was tumed to make the surface suitable for testing. Experiments have been carried out with a conventional lathe. In addition, using a force gauge, the burnishing force is accurately determined (Fig. | }. The force gauge equipment is calibrated every 3 months. No chip penetration between the tool and the coaiact surface is prevented. This is hecause the penetration of anything betweena7 ‘A Study om the Development of Aluminum ABoys Using ... eo eos oro) a0 ifn We sro wi Duna SL StOuy ug a a4 3) Ww ame poM (aye) foyp wiopaden gps fod yy 9 amos BIA) | aa,38 S.C. Cogan etal, Fig. 1 Experimental setup the interface between the tool and the sumple adversely affects the quality of the surface. ‘The Taguchi method is used to determine optimal. reliable, and optimized param- eler combinations by reducing the number of experiments [18, 19]. The Taguchi method is x low-cost, simple, and effective method to save Gime [19]. Therefore, experiment design was done using the Taguchi method in this study. Experimental design was planned using three different levels of three control factors. As a result, the total degree of freedom grade is equal to 6. Basically, the degree of freedom must be calculated in order to be able to select the approprigte index in the Taguchi method. In this study, since the degree of freedom is smaller than 9, there is no problem in selecting Ly Taguchi orthogonal array [19]. The effect of Lhree important parameters for surface roughness of specimens was selected: mediums, forces, and feed rates. According to the Taguchi experimental design, nine experiments defined for three factors and three lavels belong to each factor (Table 2). The factors and levels used in Table 2 Taguchi experimental design ese ele #. E z z ‘Teil Tri Teil Trial “Teal elelole|elalelelA Study on tbe Development of Aluminum Alloys Using ... 319 Table 3. Process parameters and their Yirnits Fiactoes Units Lowels 1 2 3 urnishing teafium Lt Dey Boron nil Mineral oil Force: N 100 200) 0 Food rate nnainita 05 4 oz the experiments are depicted in Tuble 3. For the analysis of the experimental results. the interactions between the main factors were nol taken into-consideration and the SIN ratio was calculated for each experiment_ 2.2 Measurements ‘The surface roughness is used as a measure in determining the surface texture of the material [20]. After any test procedure applied to the workpiece, changes in the surface topography of the material occur at the micro level. The determination of these changes is very important ia terms of the mechanical properties of the part [20]. Surface roughness helps te determine the performance of any mechanical component as having the stratopic designation because surface irregularities can cause cracks or corrosion initiation. The surfuce roughness value is generally calculuted by taking into account the arithmetic mean values of the absolute values (R,) [21], Referring, to Fig. 2, the Ry value can be expressed by the following equations Fig.2) Scheme of surfose roughness [23]320 S.C. Cagan etal Wig. 3. Surface roughness meter Therefore, (5.45) 2 The surface roughness of the specimens is taken from five different parts of the Al 7075-T6 workpiece. Surface roughness tests were performed using a Mitutoyo portable roughness meter (Fig. 3). 3 Results and Discussion 3.1 Experimental Results The surfisce roughness values and calculated S/N ratios obtained after bumishing process to determine the surface roughness of AL7073-T6 aluminum alloy in different parameters (force, feed rate, environment) are presented in Table 4 ‘The signal-to-noise ratios of the surface roughness obtained in the experiments were calculated, and the variation of the resulis according to the parameters is shown in Fig. 4. As a sesult of the tests performed. it is seen thal the medium with the optimum surface roughness is the mineral oil medium. Subsaquently, it is seen that surface roughness values obtained in experiments performed in boron oil medium and dry medium, respectively, are better. When the graph is examined, it is understoodA Study oo the Development of Aluminum Alloys Using .. an Table 4 Rerulu ofexperiments and SYN ratio values, Experiments | Parameters Reals ‘Medium | Howe | Foedrac | Ra (m) | Standard SIN Ra (ira) deviation 1 Dry wo [aos £8 9.0682 =352343 2 Dy mo [ar et 9.0639 =2SH210 3 Dey soo [az 126 00825 5.79636 4 ‘Boron | ao | Ot 13 9.0708 =3TaTBZ 3 Boron | 200 | a2 al 0.0550 =TAAIS 5 Boon | 300 | O05 O86 0.0633 =2IS8TS st Mince | io | az Zit ansa7 = 307020 z Miner | 200 [ans 078 aot = 70525 8 Miner [300 [ot 0.20 9.0253 D38176 Main Effects Plot for SV ratios Mean of SV ration = —~ ] as 04 Ty Gemal Medal 100 oom mS ‘Sgratlo-ma Semin tae Fig 4) Change of surface roughness results 90 calculated signal-to-noise ratios that surface roughness value generally decreases as the force value increases. The change in the surface roughness was negligible since the force value increased from 200 to 300.N. This is due to the increase of the compression on the surface of the Al 7075-T6 aluminum alloy workpiece and the processing of the subsurface layer hy compression of the cavitation [22, 23]. The surface roughness value in experiments with a force value of 200 N is the most appropriate value. When the graph is analyzed in terms of progress, il is observed that the surface roughness value is the best in the case where there is no significant difference in the surface roughness values between the speed of progression of £105 und 0.2, but the speed of progression ismm S.C. Cogan etal, 0.1. Considering the SIM ratio, the optimized parameters of burnishing process for fulfillment optimum surface roughness are the bumishing force: 200 N, medium: mineral oil, and feed rate: 0.1 mm/min. The S/N satios to surface roughness results were oblained using the Minitab 18 program. 3.2 Analysis of Variance (ANOVA) From ANOVA, the aim is to determine how the examined factors influence the selected ouipat values to measure quality and how the different levels cause variabil- ity. According to the applied ANOVA in this study, it is observed that the bumishing medium (4.8%). the force (68.9%), and feed rate (15.6%) play roles in minimizing the surface roughness {Table 5). When the results of the tests applied to the Al T075- Té workpiace are analyzed, it is determined that the factor that most impresses the surface roughness value is the force. Contribution ratio of the burnishing parameters is shown in Fig. 5. The F test is used to determine which finishing parameters are more effective for outputs. Ia general, there is.a relationship between the aumerical Table S$ ANOVA recalls for sutiace roughnces Parameters Degrees of froedum | SS ‘MS F value | Contribution (%) Burnishing ZF o.1so7 | ao7ss4 | 0.46 4s neti ome (N} 2 ziste | Loess | ase | aa Food rate z asa | o2eies | 149 15.6 frend} Error 2 osu7 | oreo Toul ® ORT ay eFore mFeediae © Medum Coven Ye Fig. Contribution perccntage of the burnishing parametersA Study on the Development of Aluminum Alloys Using ... 3 value of F and the output effect of the bumishing parameters. The greater the numer- ical value of the F value of any parameter, the greater the effect of that parameter on the output. It has been determined that the most effective factor contributing to surface roughness is the bumishing force 4 Conclusions In this chapter, a study has been carried owt on the improvement of the surface of the Al 7075-Té workpiece by mechanical methods. Experiments were curried out using the burnishing process. which is one of the mechanical surface improvement processes. The Taguchi method was used in the experimental design. This method is preferred because it decreases the number of experiments and provitles advantages in terms of time and money. The results obtainad in this study in which different parameters (medium. force, and feed rate) are examined are given below. © Optimum parameters were determined according to the analysis of the SYN ratios calculated by considering the surface roughness values. The. optimum surface roughness acconding to the experiments was obtained in the following parameters the bumishing force: 200, the medium: mineral oil, and feed rate: 0.1 mm/min. © According to the resultsof ANOVA. the effect of the force on the surface roughness ‘was 68.99, Feed ratio and the effect of the medium on surface roughness are 5.6 and 4.8%, sespectively. The force and feed rateare substantial forsurface roughness of Al 7075-T6 workpiece muterial. Generally, the surface roughness of the Al 7075-16 workpiece material used in the experiments is improved as tha force increases. This is due to the increase of the compression on the workpiece surface and the processing of the subsurface layer by compression of the cavitution. However, as the force increases toc much, the surface quality is beginning to deteriorate. The surface quality does not seem to be very goad when the feed mute is low or high. The optimum surface roughness was derived from the experimental results in mineral oi! medium, Boron oil is the medium where the best surface roughness value is obtained after mineral oil medium. The dry mediam was also found to have the worst results, References |. Zainal A, Yarid M2018) Review of development towards minimum quantity lebricution and high speed machining of alumioum 7075-T6.J Adv Manuf Technol 12(1}-125-142 2. 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