Dış Çap Tornalama Sırasında Takım Tutucu Sistemlerinde Bağlama Koşullarının Temas Davranışı ve Yapısal Kararlılık Üzerindeki Etkilerinin Sayısal Modellenmesi

Abstract

Takım sıkma sistemlerinin mekanik kararlılığı, takım tutucu–kalemlik arayüzündeki temas koşulları tarafından belirlenmekte olup bu koşullar doğrudan cıvata kaynaklı ön yükleme kuvvetleri tarafından kontrol edilmektedir. Üniversal torna tezgâhlarında gerçekleştirilen dış tornalama operasyonlarında, bağlama cıvatalarının manuel olarak sıkılması ön yükleme asimetrisine neden olabilir ve bu durum düzgün olmayan temas basıncı dağılımlarına yol açabilir. Bu çalışma, cıvatalı bir takım tutucu sisteminde bağlama koşulları, temas davranışı ve yapısal kararlılık arasındaki ilişkiyi incelemek amacıyla sayısal bir modelleme yaklaşımı sunmaktadır. Cıvata sıkma işlemini ve sonrasında kesme kuvvetlerinin uygulanmasını simüle etmek için ön gerilmeli bir sonlu eleman modeli geliştirilmiş ve temas durumunun değişimi değerlendirilmiştir. Toplam sıkma torkunun, bağlama cıvataları arasındaki tork oranının ve montaj yöneliminin etkileri; hafif, orta ve ağır kesme rejimleri altında sağ yönlü (RH) ve sol yönlü (LH) konfigürasyonlar için incelenmiştir. Yapısal davranışın karakterizasyonu amacıyla statik rijitlik ve ilk üç doğal frekans kullanılmıştır. İstatistiksel olarak anlamlı parametrelerin belirlenmesi için regresyon tabanlı varyans analizi uygulanmış, anlamlı yanıtlar ise Yanıt Yüzeyi Yöntemi (RSM) ile modellenmiştir. Model tahminleri ek sonlu eleman simülasyonları ile doğrulanmıştır. Sonuçlar, ön yükleme kaynaklı temas davranışının sistem tepkisini önemli ölçüde etkilediğini ve özellikle statik rijitlik ile ikinci doğal frekansın bağlama parametrelerine en yüksek duyarlılığı gösterdiğini ortaya koymuştur. Ayrıca, montaj yöneliminin teğetsel kesme kuvvetine bağlı olarak yönsel bir asimetri oluşturduğu ve bunun konfigürasyona bağlı dinamik karakteristiklere yol açtığı belirlenmiştir. Bulgular, takım tutucu davranışının yalnızca sıkma torku büyüklüğüne göre değerlendirilemeyeceğini; ön yükleme dağılımı, temas mekaniği ve montaj konfigürasyonunun birlikte ele alınması gerektiğini göstermektedir.

Keywords

• Takım tutucu sıkma sistemi
• Cıvatalı bağlantılar
• İşleme kararlılığı
• Sonlu elemanlar analizi
• Yanıt yüzeyi yöntemi
• Temas mekaniği

Supporting Institution

Bu araştırma herhangi bir dış finansman desteği almamıştır.

Ethical Statement

Bu makale, yazar tarafından insan katılımcılar veya hayvanlar üzerinde gerçekleştirilen herhangi bir çalışma içermemektedir

Thanks

Yazar, bu araştırmayı destekleyen akademik ortamı sağlamasından dolayı Kocaeli Üniversitesi’ne teşekkür eder.

Numerical Modelling of Clamping Condition Effects on Contact Behavior and Structural Stability in Toolholder Systems during External Cylindrical Turning

Abstract

The mechanical stability of tool-clamping systems is governed by contact conditions at the tool holder–tool post interface, which are directly controlled by bolt-induced preload forces. In external turning operations on universal lathes, manual tightening of clamping bolts may introduce preload asymmetry, resulting in non-uniform contact pressure distributions. This study presents a numerical modeling framework to investigate the relationship between clamping conditions, contact behavior, and structural stability in a bolted toolholder system. A pre-stressed finite element model was developed to simulate bolt tightening and subsequent cutting-force application, enabling the evaluation of contact-state evolution. The effects of total tightening torque, torque ratio between clamping bolts, and mounting orientation were examined for right-hand (RH) and left-hand (LH) configurations under light, medium, and hard cutting regimes. Static stiffness and the first three natural frequencies were used to characterize the structural response. Regression-based analysis of variance was performed to identify statistically significant parameters, and significant responses were modeled using Response Surface Methodology (RSM). Model predictions were verified through additional finite element simulations. The results showed that preload-induced contact behavior strongly influences system response, with static stiffness and the second natural frequency exhibiting the highest sensitivity to clamping parameters. In addition, mounting orientation generated directional asymmetry relative to the tangential cutting force, leading to configuration-dependent dynamic characteristics. The findings demonstrate that tightening torque magnitude alone is insufficient to evaluate toolholder behavior; preload distribution, contact mechanics, and mounting configuration must be considered together to accurately describe clamped interfaces.

Keywords

• Toolholder clamping
• Bolted joints
• Machining stability
• Finite element analysis
• Response surface methodology
• Contact mechanics

Supporting Institution

This research received no external funding.

Ethical Statement

This article does not contain any studies involving human participants or animals performed by any of the authors.

Thanks

The author acknowledges Kocaeli University for providing an academic environment that supported this research.

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