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Öğe Analytical Modeling Methods in Machining: A State of the Art on Application, Recent Challenges, and Future Trends(Springer Heidelberg, 2024) Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Sarikaya, Murat; Gunay, Mustafa; Boy, Mehmet; Yasar, Nafiz; Demirsoz, RecepInformation technology applications are crucial to the proper utilization of manufacturing equipment in the new industrial age, i.e., Industry 4.0. There are certain fundamental conditions that users must meet to adapt the manufacturing processes to Industry 4.0. For this, as in the past, there is a major need for modeling and simulation tools in this industrial age. In the creation of industry-driven predictive models for machining processes, substantial progress has recently been made. This paper includes a comprehensive review of predictive performance models for machining (particularly analytical models), as well as a list of existing models' strengths and drawbacks. It contains a review of available modeling tools, as well as their usability and/or limits in the monitoring of industrial machining operations. The goal of process models is to forecast principal variables such as stress, strain, force, and temperature. These factors, however, should be connected to performance outcomes, i.e., product quality and manufacturing efficiency, to be valuable to the industry (dimensional accuracy, surface quality, surface integrity, tool life, energy consumption, etc.). Industry adoption of cutting models depends on a model's ability to make this connection and predict the performance of process outputs. Therefore, this review article organizes and summarizes a variety of critical research themes connected to well-established analytical models for machining processes.Öğe Application of regression and artificial neural network analysis in modelling of tool-chip interface temperature in machining(Pergamon-Elsevier Science Ltd, 2011) Korkut, Ihsan; Acir, Adem; Boy, MehmetIn this paper, the regression analysis (RA) and artificial neural network (ANN) are presented for the prediction of tool-chip interface temperature depends on cutting parameters in machining. The RA and ANN model for prediction tool-chip interface temperature are developed and mathematical equations derived for tool-chip interface temperature prediction are obtained. The tool-chip interface temperature results obtained from mathematical equations with RA and ANN model and the experimental results available in the literature obtained by using AISI 1117 steel work piece with embedded K type thermocouple into the uncoated cutting tool (Korkut, Boy, Karacan, & Seker, 2007) are compared. The coefficient of determination (R-2) both training and testing data for temperature prediction in the ANN model are determined as 0.999791289 and 0.997889303 whereas; R-2 for both training and testing data in the RA model are computed as 0.999063 and 0.999427, respectively. The correlation obtained by the training ANN model are better than the one obtained by training RA model. The training ANN model with the Levenberg-Marquardt (LM) algorithm provides more accurate prediction and is quite useful in the calculation of tool-chip interface temperature when compared with the trained RA method in machining. On the other hand, prediction values obtained the testing RA model is slightly better performance than the testing ANN model. The results show that the tool-chip interface temperature equation derived from RA and ANN model can be used for prediction. (C) 2011 Elsevier Ltd. All rights reserved.Öğe APPLICATION OF THE TAGUCHI METHOD TO OPTIMIZE THE CUTTING CONDITIONS IN HARD TURNING OF A RING BORE(Inst Za Kovinske Materiale I In Tehnologie, 2015) Boy, Mehmet; Ciftci, Ibrahim; Gunay, Mustafa; Ozhan, FeridunThis paper is focused on optimizing the cutting conditions for the surface roughness, inner-diameter error and roundness obtained in hard turning of an inner ring bore. The hard-turning experiments were conducted on hardened and tempered AISI 52100 bearing rings using the L9 orthogonal array on a CNC lathe. The cutting speed, feed rate and number of the machined part were selected as control factors. The optimum cutting conditions were determined using the signal-to-noise (SIN) ratio. S/N ratios were calculated using the lower-the-better approach. An analysis of variance (ANOVA) was also employed to determine the level of the effect of the control factors for the surface roughness, inner-diameter error and roundness. The statistical analysis showed that the feed rate was the most significant factor for the surface roughness while the cutting speed was the most significant factor for the roundness and inner-diameter error. Finally, the optimum cutting conditions were further confirmed with confirmation tests.Öğe Comprehensive analysis of tool wear, surface roughness and chip morphology in sustainable turning of Inconel-601 alloy(Elsevier Sci Ltd, 2023) Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Guenay, Mustafa; Boy, Mehmet; Yasar, Nafiz; Demirsoez, Recep; Ross, K. Nimel SwornaThe objective of this research was to explore the impact of various cooling conditions on machinability, as potential alternatives to traditional cooling methods. To achieve this aim, a series of experiments were performed, where dry machining, minimum quantity lubrication (MQL), nanofluids, cryogenic (cryo) cooling, and hybrid cooling (cryo+nano MQL) methods were tested. Under distinct nanofluids conditions hBN(0.2 %) + graphene(0.2 %) performed well and overall cryo+nano MQL produced better result in terms of tool wear, microhardness, surface and chip morphology. The results demonstrated that the cooling effect of the Cryo-MQL regime, which maintains the cutting temperature at a tolerable level and preserves the lubricant performance of the MQL, is the cause of the lowest Vb value of 90 & mu;m.Öğe The effect of drilling parameters for surface roughness in drilling of AA7075 alloy(E D P Sciences, 2017) Yasar, Nafiz; Boy, Mehmet; Gunay, MustafaAA7075 aluminum alloy has been very popular significantly interest in the production of structural components in automotive and aviation applications due to its high strength, low density, good plasticity and better machinability comparable to many metals. Particularly, final products must have uniformly high quality to ensure essential safety standards in the aircraft industry. The optimization of hole quality which can variable according to tool geometry and drilling parameters is important in spite of high machinability rate of AA7075 alloy. In this study, the effects of drilling parameters on average surface roughness (Ra) has been investigated in drilling of AA7075 with tungsten carbide drills. Machining experiments were performed with three different drill point angles and three different levels of cutting parameters (feed rate, cutting speed). The effects of drilling parameters on thrust force has been determined with ANOVA in %95 confidence level. Feed rate was determined as the most important factor on Ra according to ANOVA results. Moreover, it was shown that increasing feed rate leads to increase of Ra while increasing drill point angle leads to decrease of Ra. The optimum surface roughness was obtained with point angle of 130 degrees, cutting speed of 40 m/min and feed rate of 0.1 mm/rev, thereby the validity of optimization was confirmed with Taguchi method.Öğe The effect of machining conditions on surface roughness and burr formation in milling of aisi 304 cast stainless steel(2022) Boy, Mehmet; Avci, MürselAISI 304 quality stainless steels are a very common type of stainless steel because they have high mechanical properties and high corrosion resistance. Stainless parts with complex and large dimensions are produced by the casting method. The machinability of stainless steels produced by casting is even more difficult than forging methods. In this study, the effects of three different cutting speeds, feed rates and constant cutting depth on the surface roughness and burr formation in dry and mist cold air (MCA) conditions were investigated in milling of AISI 304 stainless cast steel. As a result, an improvement between 15% and 48% was achieved in the average surface roughness (Ra) obtained in machining with MCA compared to dry machining conditions. In both cutting conditions, the increasing feed rate increased the burr height, while the increase in cutting speed decreased the burr height. MCA application provided an average of 9% reduction in burr height.Öğe Impact of hybrid cooling approach on milling and surface morphological characteristics of Nimonic 80A alloy(Elsevier Sci Ltd, 2022) Ross, Nimel Sworna; Gopinath, C.; Nagarajan, Srinivasan; Gupta, Munish Kumar; Shanmugam, Ragavanantham; Kumar, M. Saravana; Boy, MehmetPoor surface traits, short insert life, high manufacturing costs, and low productivity are associated with the machining of nickel alloys. Cutting fluids have well-known positive and negative effects on machinability performance. As a result, the machining industry has developed green cutting environments such as vegetable oil assisted minimum quantity lubrication (MQL) and cryogenic cooling. Despite the fact that MQL and cryogenic approaches can replace mineral oil-based flooding, their lack of lubrication and cooling properties at high speeds have prompted a search for a new hybrid approach (CO2 + MQL) that provides adequate cooling/lubrication (C/L). Moreover, as of now, no information concerning the effects of hybrid cooling on milling of Nimonic-80A is existing. To test the viability, the machining of Nimonic-80A under hybrid C/L was compared to other cutting environments (MQL and cryogenic). As crucial machinability factors, temperature, power consumption, surface and subsurface characteristics were thoroughly examined. Hybrid condition curtailed the burr formation, which paves the way for a reduction in specific cutting energy (SCE). The experimental results indicate that the hybrid condition considerably decreases the temperature and SCE by 34-53% and 17-19% in comparison with the MQL condition. Peak widening and intensity reduction were seen in the XRD examination, but no phase transition was found. Smaller grain size shows the superiority of hybrid environment.Öğe Influence of duplex jets MQL and nano-MQL cooling system on machining performance of Nimonic 80A(Elsevier Sci Ltd, 2021) Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Boy, Mehmet; Yasar, Nafiz; Krolczyk, Grzegorz M.; Gunay, MustafaNickel based super alloys are considered as difficult to machine materials. These days, the sustainable cooling system are applied at the cutting zone for enhancing the machining performance of nickel based super alloys. Therefore, the present work focusses on the machining aspects of Nimonic 80A under different cooling conditions. Moreover, the turning experiments were performed under dry, minimum quantity lubrication (MQL different positions) and nano-MQL (different positions) conditions and the influence of nozzle position during MQL and nano-MQL were investigated. The tool wear, surface roughness, mechanism promoting tool wear, power consumption and chips morphology were investigated under these subjected conditions. The outcomes of this study state that the position of MQL nozzles plays an important role to improve the machining performance of Nimonic-80 alloy. The total tool wear is approximately 60% better for nano-MQL (mixed direction) than dry conditions. The results also stated that abrasion and adhesion are prompting tool wear mechanisms observed under dry conditions.Öğe Investigation of chip-back temperature during machining depending on cutting parameters(Elsevier Sci Ltd, 2007) Korkut, Ihsan; Boy, Mehmet; Karacan, Ismail; Seker, UlviIn this study, measurement of the chip-back temperature developed during cutting was investigated using an embedded thermocouple into the cutting tool. AISI 1117 steel was used as the workpiece material and a K type thermocouple was used for the temperature measurement. The cutting tool used was uncoated and without chip braker and in the form of SCMW 12 M508-S217 according to ISO 1832. This cutting tool was fixed on a tool holder in the form of SSBCR 25 25 M12 and the side cutting edge angle during tests was 75 degrees as suggested in ISO 3685. The cutting tests were carried out on a Johnford TC35 CNC turning center. In selecting the cutting parameters, the reference values indicated in ISO 3685 were used. In order to locate the thermocouple on the cutting tool, a Flir Systems Therma Cam thermal camera was used. The results showed that increasing cutting speed, feed rate and depth of cut resulted in increase in the temperature at the back rake surface. However, cutting speed had the most influence on the temperature. (C) 2006 Elsevier Ltd. All rights reserved.Öğe Investigation of machinability indicators during sustainable milling of 17-4PH stainless steel under dry and MQL environments(Sage Publications Ltd, 2023) Yurtkuran, Hakan; Boy, Mehmet; Gunay, Mustafa17-4PH steel, which has the perfect combination of corrosion resistance and high mechanical properties, is especially preferred in defense and aerospace applications, but its machinability is poor. Thus, an extensive research has been conducted on its milling under sustainable cutting regimes (dry and minimum quantity lubrication_MQL) to contribute to both more efficient use and sustainable machining. First, the changes in resultant cutting force (Fr), the average surface roughness (Ra), the mean roughness depth (Rz) and total energy consumption (Pc-T) were investigated after the experiments performed by applying the L-18 orthogonal array. Subsequently, machining conditions were optimized for the minimization of machinability indicators with the Taguchi-based grey relational analysis technique. Finally, the predictive models for these indicators were developed by regression analysis. The order of importance for Fr and Pc-T was the depth of cut and feed, while for Ra and Rz this ordering was found to be feed rate and cutting regime. Short curved chips formed in MQL cutting regime contributed positively to the minimization of the considered machinability indicators. Although the energy consumption due to spindle speed increased with increasing cutting speed in dry cutting environment, the decrease in material strength resulted in a decrease in Pc-T. Since the cooling effect of MQL reduces the cutting temperature, material softening and thus the expected decrease in cutting resistance could not be achieved, so the decrease in Pc-T was not as much as dry cutting. Optimum machining conditions were determined as MQL cutting regime, the cutting speed of 120 m/min, the cutting depth of 0.5 mm and feed rate of 0.05 mm/rev. The determination coefficients of the predictive models developed by regression analysis showed that these models can be used safely in up milling.Öğe Machining characteristics investigations of duplex stainless steel by considering dual effect of chip breaker and cooling conditions(Sage Publications Ltd, 2022) Ascioglu, Mumin; Boy, MehmetDuplex stainless steels (DSSs) use in many applications because of their superior properties like high corrosion, good strength, and low cost. On the other hand, machinability of DSSs is very low due to its superior ductility. This study investigates optimization of cutting parameters, cutting environments (dry and cold air), and chip breaker forms by Taguchi-Grey relational analysis in turning of 2205 grade DSS. The turning tests were conducted using Taguchi's L16 mixed design by measuring and evaluating the cutting force components and surface roughness criteria (Ra and Rz). When turning of DSS2205 material in medium cutting condition, it is suitable to use low feed rate and high cutting speed for reducing of cutting force and surface roughness. In addition, it was shown that the chip breaker form is as important as the cooling medium in terms of minimizing Built-Up-Edge (BUE), which negatively affects the machinability outputs. Grey relational grade (GRG) indicated that the optimum results for all cutting conditions were the cutting speed of 160 m/min, the feed rate of 0.15 mm/rev, GM chip breaker, and cold air cutting environment. Experimental and ANOVA results indicated that the feed rate is the most important parameter on turning of DSS2205, followed by chip breaker, and cutting environment.Öğe Measurement and analysis of machining induced tribological characteristics in dual jet minimum quantity lubrication assisted turning of duplex stainless steel(Elsevier Sci Ltd, 2022) Gupta, Munish Kumar; Boy, Mehmet; Korkmaz, Mehmet Erdi; Yasar, Nafiz; Gunay, Mustafa; Krolczyk, Grzegorz M.In this work, the sustainable machining approach is promoted by implementing the dry and minimum quantity lubrication (MQL) cooling conditions in the turning of duplex stainless steel. Initially, the turning experiments were performed under dry as well as MQL conditions and then, the influence of different positions of MQL nozzles on tribological and machining performance of 2205 duplex steel was investigated. The cutting parameters were kept fixed and the performance is evaluated in terms of surface roughness, micro-hardness, energy consumption, tool wear, machined surface microstructure and chips morphology. The results demonstrated that the highest average surface roughness values were obtained under dry conditions, with a value of 2.20 mu m while MQL (flank + rake directions) produces the lowest surface roughness value of 1.55 mu m with an improvement of 30%. Moreover, dual-jet MQL gives the lowest energy consumption (229 kJ) and tool wear (0.15 mm) with 23.67% and 52.38% enhancement, respectively.Öğe A novel method for improving drilling performance of CFRP/Ti6AL4V stacked materials(Springer London Ltd, 2021) Yasar, Nafiz; Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Boy, Mehmet; Gunay, MustafaIn the aviation and structural industries, the requirement of smooth holes is an important safety problem. Since holes are a part of the joints made with fasteners, they affect the fatigue strength of the structure. Therefore, it is necessary to be very selective in terms of cutting parameters and cutting tools, especially in drilling metal/composite or composite/metal stacked materials. In this context, cutting conditions in conventional machining methods should be optimized or novel machining methods should be applied. In this context, this study minimized the limitations in machining of carbon fiber-reinforced composite (CFRP)/Ti6Al4V alloy stack material and the delamination problem that occurs especially in composite laminates. For this purpose, cutting conditions have been optimized for each of CFRP/Ti6Al4V alloy material, depending on the thrust force (Fz), surface roughness (Ra), and delamination factor (Fd) obtained by preliminary tests. The drilling tests were performed at the cutting speed of 60 m/min, the feed rate of 0.05 mm/rev for CFRP material, the cutting speed of 15 m/min, and the feed rate 0.05 mm/rev for Ti6Al4V material. The novel method for this study is that the tool was kept in the air for 1 min after each 4 mm drilling of Ti6Al4V alloy to cool the tool during the rebounds to the safe approach distance. Finally, according to the optimized cutting parameters, Fz, Ra, and Fd were assessed to evaluate the performances of cutting tools in the drilling of CFRP/Ti6Al4V stacked material. According to the experimental results and images of the digital camera and SEM device, flank wear and cracking as the wear type in the U-WC tool; flank wear, cracking, and BUE as the wear type in the TiAlN-coated tools; and outer corner wear and coating removal in diamond-coated tools. Moreover, when the tool performance is evaluated according to the cutting tool tip angle, the highest amount of wear was seen in cutting tools with 140 degrees point angle.Öğe Numerical and experimental investigations of built orientation dependent Johnson-Cook model for selective laser melting manufactured AlSi10Mg(Elsevier, 2021) Akturk, Murat; Boy, Mehmet; Gupta, Munish Kumar; Waqar, Saad; Krolczyk, Grzegorz M.; Korkmaz, Mehmet ErdiPowder bed fusion based additive manufacturing techniques involve melting or sintering of powder particles via laser beams to join them in order to attain desired shapes. This study aims to provide basis for material constitutive parameters of widely used aluminum alloy AlSi10Mg alloy. Initially, tensile samples of AlSi10Mg alloy samples were manufactured by using SLM technology. Afterwards, through quasi-static and high temperature tensile tests, an attempt has been made to determine the Johnson-Cook material model of AlSi10Mg. in order to conduct quasi-static tensile tests, strain rates of 10(-3) s(-1), 10(-2) s(-1) and 5 x 10(-2) s(-1) were considered and tests were conducted at ambient temperature. Whereas, for high temperature tensile tests 24,150, 300 degrees C temperature values were considered at the reference strain rate value of 10(-3) s(-1). The numerically simulated tensile results achieved by using the established Johnson-Cook model were then compared with experimental results. It was observed that the maximum error between the test and simulation results was around of 7.5%. The error percentage is well within the acceptable, thus proving the accuracy of the established material model. (c) 2021 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).Öğe On tribological characteristics of TiC rollers machined under hybrid lubrication/cooling conditions(Elsevier Sci Ltd, 2022) Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Demirsoz, Recep; Boy, Mehmet; Yasar, Nafiz; Gunay, Mustafa; Ross, Nimel SwornaThe titanium carbide is considered as a hard to cut material and it is very helpful in critical applications especially in guide roller applications. This study investigated the machining based tribological characteristics of TiC rollers during hard turning under sustainable cooling/lubrication conditions. Surface quality, power consumption, tool wear, microstructural changes, microhardness after machining, and SEM-EDX analysis were evaluated under dry, minimum quantity lubrication (MQL), cryogenic and hybrid cryo+MQL environments. Although the surface quality did not meet the expectations in dry cutting, MQL improved slightly than cryo methods. However, the best surface quality, the smallest tool wear and power consumption was obtained in the hybrid cryo+MQL lubrication/cooling method.Öğe Peek-cf30 termoplastik malzemenin delinmesinde delme parametrelerinin etkileri: itme kuvveti, yüzey pürüzlülüğü ve delaminasyon(2022) Boy, MehmetBu çalışmada, Poli-eter-eter-keton (PEEK)-CF30 kompozit malzemenin kaplamasız HSS matkapla delinmesinde oluşan itme kuvveti, yüzey pürüzlülüğü ve delaminasyon faktörünün kesme parametrelerine göre değişimleri araştırılmıştır. Delme deneyleri üç farklı kesme hızı (40, 80, 120 m/dk) ve ilerleme miktarı (0.1, 0.15, 0.2 mm/dev) kullanılarak kuru işleme şartlarında yapılmıştır. Delmede oluşan itme kuvvetleri Kistler dinamometre ve ekipmanlarıyla ölçülmüş ve elde edilen sonuçların aritmetik ortalaması alınarak analiz edilmiştir. Delik yüzeyinde oluşan pürüzlülük ile delik çıkışında oluşan delaminasyon hasarları ölçülmüştür. İlerleme miktarının artmasıyla itme kuvvetinde %3-%25’lik artış olurken, kesme hızının artmasıyla itme kuvvetlerinde %9-%28 aralığında artışlar görülmüştür. Kesme hızındaki azalma ve ilerleme miktarındaki artışla birlikte yüzey kalitesinde iyileşme olurken, delaminasyon faktöründe artış görülmüştür. En düşük yüzey pürüzlülüğü 40 m/dk kesme hızı ve 0.2 mm/dev ilerlemede 1.18 µm, en yüksek yüzey pürüzlülüğü 120 m/dk kesme hızı ve 0.1 mm/dev ilerlemede 2.96 µm olarak elde edilmiştir.Öğe Performance evaluation of coated ceramic tools in nano-MQL assisted turning of powder metallurgical manufactured Bohler K490 steel(Springer India, 2022) Boy, MehmetHard machining of Bohler steel is becoming important over years. This study aims to improve the machining performance of coated ceramic cutting tool under the turning of powder metallurgical hardened (from 30 to 60 HRC) Bohler K490 steel. The turning experiments were performed in dry, MQL, and nano-MQL environments using coated ceramic inserts. The machining parameters were chosen to be constant in all conditions, with a cutting speed of 150 m/min and feed rate of 0.1 mm/min and a depth of cut of 0.2 mm. Average surface roughness of machined surfaces, the tool wear of coated ceramic inserts, total power consumption in machining and chip morphology were evaluated for all cutting environments to see the effect of MQL, nano-MQL and the positions of their nozzles. As a result, the best values of tool wear, surface quality and power consumption were obtained by using the nano-MQL conditions, especially the dual jet nano-MQL technique.Öğe Performance of MQL and Nano-MQL Lubrication in Machining ER7 Steel for Train Wheel Applications(Mdpi, 2022) Camli, Kerem Yavuz; Demirsoz, Recep; Boy, Mehmet; Korkmaz, Mehmet Erdi; Yasar, Nafiz; Giasin, Khaled; Pimenov, Danil YurievichIn the rail industry, there are four types of steel grades used for monoblock wheels, namely ER6, ER7, ER8 and ER9. ER7 steel is manufactured in accordance with the EN13262 standard and is utilized in European railway lines. These train wheels are formed by pressing and rolling after which they are machined using turning process to achieve their final dimensions. However, machining ER7 steels can be challenging due to their high mechanical properties, which can facilitate rapid tool wear and thermal cracking. Therefore, while the use of coolants is critical to improving their machinability, using conventional flood coolants adds extra operational costs, energy and waste. An alternative is to use minimum quantity lubrication (MQL) cooling technology, which applies small amounts of coolant mixed with air to the cutting zone, leaving a near-dry machined surface. In the current study, preliminary tests were undertaken under dry conditions and using coated carbide inserts to determine the optimal cutting parameters for machining ER7 steel. The impact of the cutting speed and feed rate on surface roughness (R-a), energy consumption and cutting temperature were investigated and used as a benchmark to determine the optimal cutting parameters. Next, additional machining tests were conducted using MQL and nano-MQL cooling technologies to determine their impact on the aforementioned machining outputs. According to preliminary tests, and within the tested range of the cutting parameters, using a cutting speed of 300 m/min and a feed rate of 0.15 mm/rev resulted in minimal surface roughness. As a result, using these optimal cutting parameters with MQL and Nano-MQL (NMQL) cooling technologies, the surface roughness was further reduced by 24% and 34%, respectively, in comparison to dry conditions. Additionally, tool wear was reduced by 34.1% and 37.6%, respectively. The overall results from this study demonstrated the feasibility of using MQL coolants as a sustainable machining alternative for steel parts for rail wheel applications. In addition, the current study highlight the enhanced performance of MQL cooling technology with the addition of nano additives.Öğe Sertleştirilmiş rulman bileziklerinin seramik ve CBN kesici takımlarla işlenmesi(Karabük Üniversitesi, 2015) Boy, Mehmet; Çiftçi, İbrahimBu çalışmada, sertleştirilmiş AISI 52100 çeliğinden üretilen iç ve dış rulman bileziklerinin seramik ve kübik bor nitrür (CBN) kesici takımlarla işlenmesinde kesme parametrelerinin kesme kuvveti, takım aşınması, yüzey pürüzlülüğü, kalıntı gerilme, mikroyapı, boyut ve geometrik toleranslar üzerindeki etkileri ve sert tornalama ile üretilmiş rulmanların yorulma ömürleri araştırılmıştır. İç ve dış rulman bileziklerinin işlenmesinde oluşan kesme kuvvetleri piezoelektrik esaslı bir dinamometre kullanılarak ölçülmüştür. Ayrıca, aşınmış kesici takımlar tarama elektron mikroskobu (SEM) ile incelenerek aşınma tipleri belirlenmiştir. XRD yöntemi ile iç ve dış bileziklerde oluşan kalıntı gerilmeler ölçülmüştür. İç bilezik delik çapının CBN ve seramik kesici takımla işlenmesinde radyal kuvvet bileşenlerinin diğer kuvvet bileşenlerinden daha yüksek olduğu, iç ve dış bilezik yuvarlanma yolunun işlenmesinde de kuvvet bileşenlerinin farklı bir davranış sergilediği görülmüştür. İç bilezik delik çapının işlenmesinde kesici takımda genellikle yan yüzey ve krater aşınmaları, yuvarlanma yollarının işlenmesinde de yan yüzey aşınması ve takım talaş yüzeyinde yapışmaların olduğu görülmüştür. Rulman bileziklerinin iç çap tornalanmasında oluşan yüzey pürüzlülüklerinin yuvarlanma yollarında oluşan yüzey pürüzlülüklerinden daha düşük olduğu görülmüştür. İç ve dış rulman bileziklerinde yüksek miktarda basma tipinde kalıntı gerilme oluşmuştur. Basma tipindeki kalıntı gerilmenin rulman ömrünü arttırdığı görülmüştür. Yorulma ömür testleri sonucundan sert tornalama ile üretin rulman bileziklerinden üretilen rulmanların yorulma ömürlerinin geleneksel taşlama işlemi ile üretilenlerden yaklaşık olarak yüzde elli daha fazla olduğu görülmüştür.Öğe Towards specific cutting energy analysis in the machining of Inconel 601 alloy under sustainable cooling conditions(Elsevier, 2023) Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Yilmaz, Hakan; Ross, Nimel Sworna; Boy, Mehmet; Sivalingam, Vinoth Kumar; Chan, Choon KitCurrently, the research efforts on machining indices such as tool wear, surface roughness, power consumption etc. is well reported in literature, but energy analysis based on material removal methods and machine learning has received comparatively little attention. Therefore, the present work deals with the research efforts on simultaneous reduction of specific cutting energy in sustainable machining of Inconel 601 alloy with different machine learning models. The studies were conducted using dry, minimum quantity lubrication (MQL), nano-MQL, cryogenic, and hybrid cooling methods (cryo-nano-MQL). The specific cutting energy (SCE) values were calculated based on the data obtained from power consumption and material removal rate. Subsequently, the SCE data is employed to construct the crucial maps, which are then utilized in several sophisticated machine learning models, including Multiple Linear Regression, Lasso Regression, Bayesian Ridge Regression, and Voting Regressor, to facilitate the predictive modeling of outcomes. The findings of the study indicate that the Bayesian model exhibits a comparatively reduced error rate and a closely aligned R2 value when compared to other prediction models. Moreover, as a novelty, nanoparticles addition into hybrid cooling methods (cryo + nano + MQL) also showed better performance as well as 0.3 % less specific cutting energy than only cryo method which is previously used in former studies.
