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In this study, metallurgical properties of AISI 1040 steel and high-chromium white cast iron joined using friction welding process was investigated experimentally. Scanning electron microscopy, optical microscopy, energy-dispersive spectrometry, electron backscattered diffraction, X-ray diffraction and elemental mapping analysis were used to analyze the microstructures of the weld interfaces. The joint strength was evaluated with tensile testing and microhardness, and the fracture behavior was examined by SEM. HCrWCI and AISI 1040 steel were successfully welded using the FW. Increasing rotational speed was an effective parameter on the joint quality. The diffusion of Cr, C, Mn, Mo, Si and Ni elements occurred more in high-speed joints. The increase in plastic deformation caused the formation of fine grains and increased strength. [ABSTRACT FROM AUTHOR]

The paper analyzes the failure case of welded joint for energy storage device. The energy storage devices are made up of AISI 1040 steel cases or boxes. Bulging effect in these boxes exerts tensile load on welded joint and breaks them. Root cause analysis is done and the root cause is found out to be improper throat thickness of weld. To find out the solution, problem is analyzed theoretically and simulated in ANSYS R18.1 software for a constant tensile load of 16 KN. The results show that there is a linear correlation between strength of welded joint and throat thickness. These results are validated in actual experimentation by taking tensile test on the sample specimens. The design of experiment by Taguchi is done on three variables, viz., weld current, arc voltage and wire feed rate. The results of experimentation are compared with the result from theoretical calculation and ANSYS result. Optimized parameters are selected for implementation in welding of boxes. The performance of the device under modified parameters is examined, presented and discussed. [ABSTRACT FROM AUTHOR]

In this study, the effects of chip breaker forms (E-PL, M-PL, M-PM, M-MM) on the surface roughness and cutting forces were investigated in milling of AISI 1040 steel at CNC vertical machining center. Experimental studies were performed at four cutting speeds (150, 225, 300, 375 m/min), three feed rates (0.05, 0.1, 0.15 mm/tooth) and 1 mm depth of cut in dry cutting conditions. As a result of the experiments, the best surface roughness values and the lowest cutting force values were obtained with cutting tools having chip breaker form E-PL. Surface roughness was increased for all cutting tools with the increase in feed rate and decreased with increasing cutting speed. The best surface roughness values were determined as 0,134 µm, at the cutting speed of 375 m/min and at 0,05 mm / tooth feed with E-PL coded cutting tool. In addition, it was observed that cutting force increases with the increase in feed rate and decreases with the decrease in cutting speed.

Electro-spark deposition (ESD) or low energy welding (LEW) technique allows the coating of metallic materials with different metal and alloys, conductive ceramics and conductive ceramic metal composites. It is also known as micro-joining process to improve the wear properties of the substrate or to obtain a more durable upper superficial coating. In this study, the surfaces of AISI 1040, AISI 4140 and AISI 5140 steels were coated with WC electrode at constant rotational speed and then characterized by a metallographic study. A homogeneous coating thickness was observed in microscopy studies and the formation of W2C phase in the coating layer was determined in XRD analysis. Hardness of WC coated samples increased approximately 5 times. Abrasion tests were carried out by ball-on disc method with WC–Co ball at 250 m under 5N load. In the abrasion tests with WC–Co ball, the best abrasion resistance is obtained with WC coated AISI 5140 steel, while the lowest strength is obtained with uncoated AISI 4140 steel. [ABSTRACT FROM AUTHOR]

The ball joint parts made of forged steel are quite important in the suspension system. The quality of production of ball joint parts is very important because of their role. Some basic defects can be found in the hole edge form. These defects affect the hole quality of ball joint parts. In this study, the effects of cryogenic processing on the wear of AISI D2 punches and the effects of punch wear on the hole edge geometry of hot forged AISI 1040 steel ball joint parts were investigated. The hole geometry changes are generally associated with punch wear and process parameters. For the purpose of investigation, piercing was carried out using an eccentric press with AISI D2 tool steel punches on 6.0 mm-thick ball joint pieces. The punches were traditionally heat treated. Some of the punches were cryogenic-treated at -145 °C in addition to the conventional heat treatment. Weight loss values were measured to assess the punch wear, and SEM and OM images were analysed. At the end of the industrial piercing process, it was found that the D2 tool steel punch wear decreased with cryogenic process applied and the size changes in the hole edge geometry of the punched 1040 hot forged steel parts turned out to be less marked. [ABSTRACT FROM AUTHOR]

Bu araştırmada, 46 HRc sertlikteki silindir şekle sahip AISI 1040 çeliği için dörder seviyeden oluşan kesme hızı, ilerleme ve talaş derinliği parametrelerine göre Taguchi L16 deney tasarımı oluşturulmuştur. Tornalama sonucu oluşan yüzey pürüzlülüğü (Rt) değerleri ölçülmüştür. Ölçülen Rt değerleri için MINITAB14 programından yararlanılarak çoklu regresyon modelleri oluşturulmuş ve Taguchi analizleri gerçekleştirilmiştir. Rt için oluşturulan regresyon modellerinde deney sonuçlarına en yakın sonuçlar %99.8 belirtme katsayısı ile ikinci dereceden çoklu regresyon modeliyle elde edilmiştir. Taguchi tasarımında sinyal/gürültü (S/N) oranları belirlendi. ANOVA analizinde sırası ile ilerleme, talaş derinliği ve kesme hızının Rt değerine %95 güven düzeyinde etki ettiği elde edilmiştir. Oluşturulan regresyon modelleri ve Taguchi analizi sonucu Rt üzerinde en etkin parametrenin ilerleme olduğu sonucuna varılmıştır.

Bu çalışmada; AISI 1040 çeliği, elektrik ark ve MIG ile kaynatılıp, numuneler üretilmiştir. Kaynaklı ve kaynaksız numuneler tam tavlama, normalizasyon, menevişleme ve gerilim giderme işlemlerine tabi tutulmuşlardır. İşleme tabi tutulan ve herhangi bir ısıl işlem yapılmayan numunelere çekme, üç nokta eğme, çentik darbe ve sertlik testleri yapılmıştır. Numunelerin çekme şekil değiştirmeleri kaynaksız parçaların, kaynaklı parçalara nazaran daha yüksek elde edilmiştir. Kaynaksız ve elektrik ark kaynağı yapılıp, gerilim giderme işlemi görmüş numunelerin akma ve çekme dayanım değerleri birbirlerine yakın elde edilmiştir. Martenzitik yapının dışarıda sert, içeri gittikçe yumuşak bir yapı haline geldiği görülmüştür. Ölçülen sertlik değerlerinin, kaynak dolgu metalinin ortasından başlayıp genelde dışarıya doğru bir artış gösterdiği gözlenmiştir.

Hole-making is one of the most important processes of metal shaping domain. Although, drilling is a commonly used approach to cut holes in metallic parts, the process cannot be completed with the cutting action of one drill bit if the work material is hard and diameter of the hole is large. Usually, a drill having diameter equal to the required diameter of the hole is utilized to enlarge a predrilled hole of a smaller diameter. In this work, we have investigated sustainability of using another method of enlarging a pre-drilled hole, namely side and end milling and compared it with the drilling-based approach. The work material used in the study is a high carbon steel, which is heat-treated to two distinct levels of surface hardness. Besides process type and work material hardness, the other two parameters tested in the investigation are cutting speed and depth of hole. A total of 16 experiments were performed to generate data regarding the sustainability measures, namely hole surface roughness, specific cutting energy and tool wear. Process choice (drilling or milling) for hole-enlargement was found to possess a significant effect on all the measured responses. Analyses carried out on the experimental data revealed that although the drilling-based option led to an immensely better surface finish, the milling-based option performed better with respect to the other measures of economic and environmental sustainability. [ABSTRACT FROM AUTHOR]

AISI 1040 steel is widely used for production of various parts. This material has been studied by many researchers. In this work, turning tests were carried out on AISI 1040 steel workpieces at five different depth of cuts, four different feed rates and 4 different cutting speeds without coolant. The influence of the cutting parameters on turned part surface roughness, vibration, sound level and machine tool motor current were examined. A full factorial experimental design method was used. The Response Surface Methodology (RSM) and Analysis of Variance (ANOVA) were used to determine the effects of input parameters on the resultant surface roughness, vibration, sound level, current. The experimental results showed that increasing feed rate increased the surface roughness, vibration, sound level and current values. The most effective cutting parameter on all the output parameters was found to be the feed rate. Furthermore as feed rate and depth of cut increased, the current value and sound level also increased. [ABSTRACT FROM AUTHOR]

Bu çalışmada, AISI 1040 çeliğinin aşındırıcı su jeti ile tornalanması esnasında işleme parametrelerinin kaldırılan talaş hacmime ve kesme derinliğine etkisi araştırılmıştır. Yapılan çalışmada deney sayısının en az olması için literatürde yapılmış olan çalışmalar göz önüne alınmış ve ön deneyler sonucu elde edilen tecrübelerle en uygun işleme parametre değerleriyle deneyler gerçekleştirilmiştir. Deneysel çalışmalarda pompa basıncı (350 MPa), aşındırıcı boyutu (Garnet formunda ve boyutu 80 mesh) ve nozul çapı (1.2 mm) sabit tutulmuştur. Ø 30 ve 240 mm ebatlarında 1040 çeliği, dört farklı aşındırıcı akış oranı (50, 150, 250 ve 350 gr/dak.), nozul mesafesi (2, 5, 8 ve 11 mm), nozul ilerleme miktarı (5, 15, 25 ve 35 mm/dak.) ve torna aynası deviri (25, 50, 75 ve 100 dev/dak.) işleme parametreleri değerlerinde işlenmiştir. Elde edilen bulgulara göre en yüksek talaş hacmi 5 mm/dak nozul ilerleme miktarında 1387,25 mm3 elde edilmiştir. En yüksek kesme derinliği ise 0,94 mm olarak 100 dev/dak torna aynası devrinde elde edilmiştir.

In this research, AISI 1040 steel whose hardness is 46 HRc was processed in CNC lathe. Taguchi L16 experiment design was created based on cutting speed, feed rate and depth of cut of which is consisted of four levels. As a result of these experiments, average surface roughness (Ra) values were measured. Multiple regression models for measured Ra values were created by using MINITAB 14 program. The closest results to the experiment results in regression models created for Ra were obtained with the quadratic regression model with the 99.8% coefficient of determination. With the regression models created, it was determined that the most effective parameters are the feed rate parameters. From mathematical equations created in the result of the experiments carried out, it was determined that the quadratic regression equation is approximately 90% correct. [ABSTRACT FROM AUTHOR]