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Simulation Supported Investigation of Special Bushing Parts Production with Alternative Production Methods

Year 2023, Issue: 51, 142 - 152, 31.08.2023
https://doi.org/10.31590/ejosat.1255048

Abstract

Product exclusive process method development studies are carried out in order to minimize the problems experienced in the supply of raw materials, serial production numbers and to search for alternative raw materials and to realize low-cost production. In this study; the special fasteners, all cross-section forms of which are produced using the machining method, have been produced with the aid of machining with the cold forming application, which is an alternative production method. Considering alternative designs were evaluated, product - die designs were created using a computer-aided simulation program (simufact.forming) for the production of all forms except the piston ring channel and the internal thread form on the outer section of the special bushing fastener by cold forging process.The designed product was simulated with the finite element method, the design accuracy was examined and the prototype product was produced. Raw material savings by the machining supported cold forming application was approximately 54% and 6 times per minute production rate increase was achieved.

References

  • Abhari, P. (2017). Numerical simulation of cold forging process with enclosed dies to avoid folding defect in forming shape, Mechanics and Advanced Technologies, Volume 80, pp. 71-77.
  • Andreasa, K., Merkleina, M. (2014). Influence of surface integrity on the tribological performance of cold forging tools, 2nd CIRP Conference on Surface Integrity, 13, 61-66.
  • Baygut, A., Çulha, O., Yağcı, T. (2022). Ön deformasyona uğratılmış hammadde kullanılarak paslanmaz çelik bağlantı elemanının simülasyon destekli soğuk dövme üretimi, Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 24(72), 689-702.
  • Bunge, H. J., Pöhlandt, K., Tekkaya, A. E., Banabic, D. (2000). Formability of Metallic Materials.
  • Çapan, L. (1996). Plastik Şekil Verme, TMMOB Makine Mühendisliği El Kitabı, 2, 170, pp.32-61.
  • Çapan, L. (2003). Metallere Plastik Şekil Verme, Çağlayan Kitabevi, 144.
  • Duman, M. (2020). Fikstür ve Aparatların Yazılım Otomasyonunun Talaşlı İmalat Yapan Bir Firmada Uygulaması, Yüksek Lisans Tezi, Isparta Uygulamalı Bilimler Üniv. Lisansüstü Eğitim Enstitüsü.
  • Geiger, M., Hansel, M., Rebhan, T. (1992). Improving the fatigue resistance of cold forging tools by FE simulation and computer aided die shape optimization, Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, 06, pp. 143-150.
  • Hsu, Quang-Cherng., Lee, Rong-Shean. (1997). Cold forging process design based on the induction of analytical knowledge , Journal of Materials Processing Technology, Volume 69, Issues 1–3, pp.264-272.
  • Hyunkee, K., Altan, T. (1996). Cold forging of steel -practical examples of computerized part and process design, Journal of Materials Processing Technology, Volume 59, Issues 1-2, 15, pp.122-131.
  • Kılıçaslan, C., İnce, U. (2016). Soğuk dövme kalıplarında meydana gelen kırılma sebeplerinin nümerik olarak incelenmesi, Mühendis ve Makina, 57, 678, pp. 65-71.
  • Knoerr, M., Lee, J., Altan, T. (1992). Application of the 2D finite element method to simulation of various forming processes, Journal of Materials Processing Technology, 33, pp.31–55.
  • Kobayashi, S., Oh, S., Altan, T. (1989). Metal Forming and the Finite Element Method, Journal of Materials Shaping Technology, 8, pp. 65-65.
  • Lee, H.C., Saroosh, M.A., Im, Y.T. (2009). The effect of shrink fitting ratios on tool life in bolt forming processes, Journal of Materials Processing Technology, Volume 209, Issues 8, pp. 3766-3775.
  • MacCormack, C., Monaghan, J. (2002). 2D and 3D finite element analysis of three stage forging sequence, Journal of Materials Processing Technology, 2002, pp. 48-56, 2002.
  • Skov-Hansen, P., Bay, N., Grønbæk, J., Brøndsted, P. (1999). Fatigue in cold-forging dies: tool life analysis, Journal of Materials Processing Technology, Volume 95, Issues 1-3, pp. 40-48, 1999.
  • Vazquez, V., Hannan, D., Altan, T. (2000). Tool life in cold forging- an example of design improvement to increase service life, Journal of Materials Processing Technology, Volume 98, Issues 1, pp. 90-96.
  • Zhuang, W., Han, X., Hua, L. (2017). Differences between traditional cold forging and cold orbital forging of a spur bevel gear”, Procedia Engineering, Volume 207, pp. 442-447.
  • Wagner, K., Putz, A., Engel, U. (2006). Improvement of Tool Life in Cold Forging by Locally Optimized Surfaces, Journal of Materials Processing Technology, pp. 206-209.

Alternatif Üretim Yöntemleri İle Özel Burç Parça Üretiminin Simulasyon Destekli Araştırılması

Year 2023, Issue: 51, 142 - 152, 31.08.2023
https://doi.org/10.31590/ejosat.1255048

Abstract

Hammadde temini, seri üretim adetlerinde yaşanan problemleri en aza indirgeyebilmek ve alternatif hammadde arayışları ile düşük maliyetli üretimin gerçekleşmesi için ürün özelinde imalat yöntemi geliştirme çalışmaları yapılmaktadır. Bu çalışmada; tüm kesit formları talaşlı imalat yöntemi kullanılarak üretilen özel bağlantı elemanının, alternatif üretim yöntemi olan soğuk dövme uygulaması ile talaşlı imalat destekli üretilmesi gerçekleştirilmiştir. Alternatif tasarımlar değerlendirildiğinde özel burç bağlantı elemanının dış kesitindeki segman kanalı ve iç diş formu haricindeki tüm formların soğuk dövme prosesiyle üretimi için bilgisayar destekli simülasyon programı (simufact.forming) kullanılarak ürün - kalıp tasarımları oluşturulmuştur. Tasarımı yapılan ürün sonlu elemanlar yöntemi ile simüle edilmiş, tasarım doğruluğu incelenmiş ve prototip ürün üretilmiştir. Talaşlı imalat destekli soğuk dövme uygulaması ile yaklaşık %54 oranında hammadde tasarrufu, dakikada 6 kat üretim artışı sağlanmıştır.

References

  • Abhari, P. (2017). Numerical simulation of cold forging process with enclosed dies to avoid folding defect in forming shape, Mechanics and Advanced Technologies, Volume 80, pp. 71-77.
  • Andreasa, K., Merkleina, M. (2014). Influence of surface integrity on the tribological performance of cold forging tools, 2nd CIRP Conference on Surface Integrity, 13, 61-66.
  • Baygut, A., Çulha, O., Yağcı, T. (2022). Ön deformasyona uğratılmış hammadde kullanılarak paslanmaz çelik bağlantı elemanının simülasyon destekli soğuk dövme üretimi, Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi, 24(72), 689-702.
  • Bunge, H. J., Pöhlandt, K., Tekkaya, A. E., Banabic, D. (2000). Formability of Metallic Materials.
  • Çapan, L. (1996). Plastik Şekil Verme, TMMOB Makine Mühendisliği El Kitabı, 2, 170, pp.32-61.
  • Çapan, L. (2003). Metallere Plastik Şekil Verme, Çağlayan Kitabevi, 144.
  • Duman, M. (2020). Fikstür ve Aparatların Yazılım Otomasyonunun Talaşlı İmalat Yapan Bir Firmada Uygulaması, Yüksek Lisans Tezi, Isparta Uygulamalı Bilimler Üniv. Lisansüstü Eğitim Enstitüsü.
  • Geiger, M., Hansel, M., Rebhan, T. (1992). Improving the fatigue resistance of cold forging tools by FE simulation and computer aided die shape optimization, Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture, 06, pp. 143-150.
  • Hsu, Quang-Cherng., Lee, Rong-Shean. (1997). Cold forging process design based on the induction of analytical knowledge , Journal of Materials Processing Technology, Volume 69, Issues 1–3, pp.264-272.
  • Hyunkee, K., Altan, T. (1996). Cold forging of steel -practical examples of computerized part and process design, Journal of Materials Processing Technology, Volume 59, Issues 1-2, 15, pp.122-131.
  • Kılıçaslan, C., İnce, U. (2016). Soğuk dövme kalıplarında meydana gelen kırılma sebeplerinin nümerik olarak incelenmesi, Mühendis ve Makina, 57, 678, pp. 65-71.
  • Knoerr, M., Lee, J., Altan, T. (1992). Application of the 2D finite element method to simulation of various forming processes, Journal of Materials Processing Technology, 33, pp.31–55.
  • Kobayashi, S., Oh, S., Altan, T. (1989). Metal Forming and the Finite Element Method, Journal of Materials Shaping Technology, 8, pp. 65-65.
  • Lee, H.C., Saroosh, M.A., Im, Y.T. (2009). The effect of shrink fitting ratios on tool life in bolt forming processes, Journal of Materials Processing Technology, Volume 209, Issues 8, pp. 3766-3775.
  • MacCormack, C., Monaghan, J. (2002). 2D and 3D finite element analysis of three stage forging sequence, Journal of Materials Processing Technology, 2002, pp. 48-56, 2002.
  • Skov-Hansen, P., Bay, N., Grønbæk, J., Brøndsted, P. (1999). Fatigue in cold-forging dies: tool life analysis, Journal of Materials Processing Technology, Volume 95, Issues 1-3, pp. 40-48, 1999.
  • Vazquez, V., Hannan, D., Altan, T. (2000). Tool life in cold forging- an example of design improvement to increase service life, Journal of Materials Processing Technology, Volume 98, Issues 1, pp. 90-96.
  • Zhuang, W., Han, X., Hua, L. (2017). Differences between traditional cold forging and cold orbital forging of a spur bevel gear”, Procedia Engineering, Volume 207, pp. 442-447.
  • Wagner, K., Putz, A., Engel, U. (2006). Improvement of Tool Life in Cold Forging by Locally Optimized Surfaces, Journal of Materials Processing Technology, pp. 206-209.
There are 19 citations in total.

Details

Primary Language Turkish
Subjects Engineering
Journal Section Articles
Authors

Alper Baygut 0000-0003-4775-1066

Early Pub Date September 10, 2023
Publication Date August 31, 2023
Published in Issue Year 2023 Issue: 51

Cite

APA Baygut, A. (2023). Alternatif Üretim Yöntemleri İle Özel Burç Parça Üretiminin Simulasyon Destekli Araştırılması. Avrupa Bilim Ve Teknoloji Dergisi(51), 142-152. https://doi.org/10.31590/ejosat.1255048