Bağlantı Elemanı Üretim Verimliliğini Artırmak İçin Soğuk Dövme Prosesinde Tasarım İyileştirme ve Simülasyon Çalışmaları

Year 2025, Volume: 25 Issue: 4, 916 - 927, 04.08.2025

Tuğçe Yağcı , Alper Baygut , Osman Çulha

https://doi.org/10.35414/akufemubid.1548540

Abstract

Bu çalışmada, özel bir bağlantı elemanının kesit geometrisinde silindirik formdan kareye değişikliği ve soğuk dövmede operasyon adım sayısının azaltılması ile üretim verimliliğinin artırılması hedeflenmiş ve üretim sırasında hammadde ve kalıpta ortaya çıkan gerilmeler incelenmiştir. Çalışmada, tasarım ve proses parametreleri simülasyon analizleri belirlenmiş, prototip üretimler gerçekleştirilmiş ve deneysel doğrulama çalışmaları yapılmıştır. Bağlantı elemanı, geleneksel proses tasarım çalışmalarıyla öngörülen 5 veya 6 operasyonla, 20MnB4 düşük karbonlu çelik hammadde kullanılarak üretilmiştir. Simülasyona dayalı tasarım çalışmalarında; kesit daralmaları, kare kesitin silindirik hammaddeden eldesi ve kafa formunun oluşturulması sırasında meydana gelen gerilme değerleri araştırılmıştır. Prototipleme sürecinde, simülasyon çalışmalarının sonuçlarına göre, iki ekstrüzyon operasyonunun tek kalıpta gerçekleştirilmesi ve optimum kalıp gerilmelerinin tespit edildiği 5 operasyonlu proses tasarımına dayanan soğuk dövme yöntemiyle üretim yapılmıştır. Araştırmanın sonucunda, sanal ve deneysel çalışmalardan elde edilen sonuçlar karşılaştırmalı olarak incelenmiştir. Sanal ve gerçek veriler arasında ortalama %98,9 düzeyinde bir uyum tespit edilmiştir. Ayrıca, kalıp maliyetinde yaklaşık %15 oranında azalma ve kafa altı kare form bölgesinin şekillendirilmesinde kullanılan kalıp ömründe %18 oranında artış elde edilmiştir.

Keywords

Soğuk dövme , Bağlantı elemanı , simülasyon çalışmaları , optimizasyon , prototip üretim

Design Enhancement and Simulation Studies in Cold Forging Process to Increase Efficiency in Fastener Production

Abstract

In this study, a modification was made to the cross-sectional geometry of a specific fastener, changing it from a cylindrical form to a square and by reducing the number of operational steps in cold forging and the stresses induced in the raw material and the die during production were examined. In the study, design and process parameters were determined through simulation analysis, prototypes were produced, and experimental validation studies were conducted. The fastener was produced using 20MnB4 low-carbon steel raw material through 5 or 6 operations as predicted by conventional process design methods. In the simulation-based design studies, the stress values occurring during cross-sectional reductions, the formation of the square cross-section from cylindrical raw material, and the head shaping process were investigated. During the prototyping process, based on the results of the simulation studies, production was carried out using the cold forging method with a 5-operation process design, in which two extrusion operations were performed in a single die, and optimal die stresses were identified. As a result of the study, it was determined that there is an average compatibility of 98.9% between the obtained virtual and real production data. Furthermore, approximately a 15% decrease in die cost and an 18% increase in die life used for shaping the head square form region were achieved.

Keywords

Cold forging , Fastener , Simulation studies , Optimization , Prototype production

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