Ultra yüksek mukavemetli çelik sacların zımba ile delme işleminin takım ömrü için Taguchi yöntemi kullanılarak optimizasyonu

Year 2025, Volume: 15 Issue: 3, 728 - 739, 15.09.2025

Onur Çoban , Kerim Mert Çelik , Murat Bayraktar , Rahman Ehvan , İlker Kuzucu

https://doi.org/10.17714/gumusfenbil.1610663

Abstract

Ultra yüksek mukavemetli sacların zımba ile delinmesinde takım ömrünün artırılması ve bu sayede bakım maliyetlerinin düşürülmesi otomotiv sektörü için çok kritiktir. Bu çalışmada zımba ömrünü etkileyen zımba hammaddesi (Vanadis 4E ve Caldie ESR), zımba kaplaması (kaplamasız, AlCrN, TiAlCN), zımba uç yuvarlatma yarıçapı (0.1, 0.3 ve 0.5 mm) ve kesme boşluğu (sac kalınlığının %15, %22 ve %30’u) parametrelerinin maksimum zımba ömrü için istatistiksel olarak Taguchi metodu ve ANOVA analizleriyle optimizasyonu ve bu sayede kazanılacak bakım maliyeti hesaplaması yapılmıştır. Taguchi metodu sonuçları en yüksek zımba ömrü için hammadde olarak Caldie ESR, kaplama türü olarak TiAlCN, uç yuvarlatma yarıçapı olarak 0.3 mm ve kesme boşluğu olarak da sacın %15’inin seçilmesi gerektiğini göstermiştir. ANOVA analizleri sonucunda ise %61.71’lik katkı oranı ile kaplama türü ve ardından %24.12’lük katkı oranı ile kesme boşluğu en etkin faktörler olarak belirlenmiştir. Yapılan istatistiksel optimizasyon sayesinde zımba ömrü 2538 işlemden 22080 işleme yükseltilirken 100000 delme işlemi için bakım maliyetlerinde yaklaşık 465819 TL’lik kazanç elde edilmiştir. Ultra yüksek mukavemetli sacların zımba ile delinmesinde zımba ömrü iyileştirmesi ve dolaylı olarak bakım maliyetlerinin minimize edilmesi için istatistiksel proses optimizasyonunun gerekliliği başarıyla ortaya konmuştur.

Keywords

Maliyet , Taguchi , Takım ömrü , Ultra yüksek mukavemetli sac , Zımba ile delme

Ethical Statement

Bu makalenin yazarları, bu çalışmada kullanılan materyal ve yöntemlerin etik kurul izni ve / veya yasal-özel izin gerektirmediğini beyan eder.

Thanks

Yazarlar, çalışmanın yürütülmesindeki destekleri için Linde Opsan A.Ş.'nin tüm çalışanlarına teşekkür eder. Yazarlar ayrıca malzeme tedarikindeki destekleri için Uddeholm firmasına teşekkürü bir borç bilir.

Optimization of punching process of ultra high strength steel sheets for tool life using Taguchi method

Abstract

Increasing tool life and thus reducing maintenance costs in hole punching of ultra-high strength sheet metal is critical for the automotive industry. In this study, the punch raw material (Vanadis 4E and Caldie ESR), punch coating (uncoated, AlCrN, TiAlCN), punch tip radius (0.1, 0.3 and 0.5 mm) and clearance (15%, 22% and 30% of the sheet thickness) parameters affecting the punch life were statistically optimised by Taguchi method and ANOVA analyses for maximum punch life and maintenance cost calculation. Taguchi method results showed that Caldie ESR should be selected as the raw material, TiAlCN as the coating type, 0.3 mm as the tip rounding radius and 15% of the sheet as the cutting gap for the highest punch life. As a result of ANOVA analyses, coating type with a contribution rate of 61.71% and then cutting gap with a contribution rate of 24.12% were determined as the most effective factors. Thanks to the statistical optimisation, the punch life has been increased from 2538 to 22080 operations, while a gain of approximately 465819 TL in maintenance costs for 100000 punching operations has been achieved. The necessity of statistical process optimisation for punch life improvement and indirectly minimising maintenance costs in hole punching of ultra-high strength sheets has been successfully demonstrated.

Keywords

Cost , Taguchi , Tool life , Ultra high strength steel , Hole punching

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