Yazar "Kuntoglu, Mustafa" seçeneğine göre listele

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    Estimation, optimization and analysis based investigation of the energy consumption in machinability of ceramic-based metal matrix composite materials
    (Elsevier, 2022) Usca, Usame Ali; Sap, Serhat; Uzun, Mahir; Kuntoglu, Mustafa; Salur, Emin; Karabiber, Abdulkerim; Pimenov, Danil Yu
    The current study aims to determine the influence of machining and production parameters during the milling of Cu/B-CrC composites. The relationship between energy consumption and cutting speed, feed rate and reinforcement ratio were investigated. For this purpose, 2d and 3d graphs for comparison of the effects of input parameters were demonstrated and analyzed. The predictability of the energy consumption during milling was measured by a fuzzy inference system (FIS). According to the graphical and optimization results, the optimum conditions to obtain the minimum energy consumption were 5% reinforcement ratio, 125 m/min cutting speed and 0.2 mm/rev feed rate. A reinforcement ratio of 52.71% was the most effective factor on energy demand followed by the feed rate (24.26%) and cutting speed (12.85%). According to the obtained results, there was a minor margin of error between the actual and predicted findings ranging from 1.6 to 2.4%. Considering the energy consumption is one of the key factors among machinability criteria, the study proposes a comprehensive approach for industrial and academic works. (c) 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
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    Influence of tool path strategies on machining time, tool wear, and surface roughness during milling of AISI X210Cr12 steel
    (Springer London Ltd, 2022) Uzun, Mahir; Usca, Usame Ali; Kuntoglu, Mustafa; Gupta, Munish Kumar
    In this study, the effect of four different machining methods consisting of Trochoidal, Follow Part, Zig, and Zig-Zag which are common in CAM package programs and used often in the industry has been investigated. Firstly, the 3D model of samples is produced in the CAD program. Models are machined in CNC milling workbench. In order to examine the effect of tool path strategies on tool life, the amount of wear loss as a criterion and the SEM images of tool wear as a supporting criterion are taken into account. According to the results, the Zig-Zag tool path strategy is the tool path that causes the highest weight loss in the cutting tool, while the Trochoidal tool path strategy causes in the least weight loss in the cutting tool. In addition, the surface roughness of the samples taken from different regions of the model and the operation time of the different tool paths are determined. In this context, the operation time of the test sample is maximum in Zig team path strategy, while it is at least in Follow part team path strategy. By examining the surface roughness, the best surface roughness values are obtained with the strategy of Follow Part and Trochoidal tool path, while the worst values are obtained in the Zig tool path strategy. As a result of the examination, the optimum tool path strategy for cutting tool life was found to be Trochoidal tool path. This work differs from the counterparts as handling the AISI X210Cr12 steel which make the paper first in determining the effect of tool path strategies on machinability. Lastly, obtained findings are useful for the organization of this type of steel in manufacturing chain of industrial companies.
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    Investigation of the Effects of Cooling and Lubricating Strategies on Tribological Characteristics in Machining of Hybrid Composites
    (Mdpi, 2022) Sap, Serhat; Usca, Usame Ali; Uzun, Mahir; Kuntoglu, Mustafa; Salur, Emin; Pimenov, Danil Yurievich
    Engineering materials are expected to contain physical and mechanical properties to meet the requirements and to improve the functionality according to their application area. In this direction, hybrid composites stand as an excellent option to fulfill these requests thanks to their production procedure. Despite the powder metallurgy method that allows for manufacturing products with high accuracy, machining operations are still required to obtain a final product. On the other hand, such materials are characterized with uncertainties in the structure and extremely hard reinforcement particles that aggravate the machinability. One of the prominent solutions for better machinability of composites is to use evolutionary cooling and lubricating strategies. This study focuses on the determination of tribological behavior of Cu-based, B-Ti-SiCP reinforced, about 5% wt. hybrid composites under milling of several environments, such as dry, minimum quantity lubrication (MQL)-assisted and cryogenic LN2-assisted. Comprehensive evaluation was carried out by considering tool wear, temperature, energy, surface roughness, surface texture and chips morphology as the machinability characteristics. The findings of this experimental research showed that cryogenic cooling improves the tribological conditions by reducing the cutting temperatures, flank wear tendency and required cutting energy. On the other hand, MQL based lubricating strategy provided the best tool wear index and surface characteristics, i.e., surface roughness and surface topography, which is related to spectacular ability in developing the friction conditions in the deformation zones. Therefore, this paper offers a novel milling strategy for Cu-based hybrid composites with the help of environmentally-friendly techniques.
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    Investigations on tool wear, surface roughness, cutting temperature, and chip formation in machining of Cu-B-CrC composites
    (Springer London Ltd, 2021) Usca, Usame Ali; Uzun, Mahir; Kuntoglu, Mustafa; Sap, Emine; Gupta, Munish Kumar
    Composites have excellent material properties such as lightness, rigidity, and strength with reinforcement of specialized materials to serve an extended field in engineering. Meanwhile, some restrictions due to the production process lead to poor machinability characteristics and show reduced surface quality, excessive cutting temperature, and tool wear. The principal aim in this study is to research the machinability characteristics of Cu matrix reinforced by B and ceramic CrC powders during dry turning operation. In addition to reinforcement ratio, cutting speed, feed rate, and depth of cut were taken into consideration according to Taguchi L-8 orthogonal array in the experimental plan. Seemingly, reinforcement ratio is the governing factor over turning parameters on flank wear, surface roughness, and cutting temperatures. For the secondary effect, cutting speed and feed rate have contributing impact on cutting temperatures and surface roughness, respectively. Lastly, reinforcement ratio has significant impact on chip formation since deformation mechanism in the material is changed with cutting initiation. Accordingly, new additives reveal unique structure which is intriguing and need to be discovered for measuring the machinability behavior of metal matrix composites.
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    Performance evaluation of AlTiN coated carbide tools during machining of ceramic reinforced Cu-based hybrid composites under cryogenic, pure-minimum quantity lubrication and dry regimes
    (Sage Publications Ltd, 2022) Sap, Serhat; Usca, Usame Ali; Uzun, Mahir; Kuntoglu, Mustafa; Salur, Emin
    In this study, the machining performance of 10 wt.% B-Ti-SiCp particles reinforced Cu-based hybrid composites were investigated under dry, minimum quantity lubrication (MQL) and cryogenic LN2 assisted environments during milling. In-depth analyses comprising of tool wear development, surface roughness, surface texture, cutting temperature, cutting energy, and chip morphologies were thoroughly performed. According to the experimental results, MQL environment was found to be most influential method to prevent build-up-edge formation. In addition, LN2 assisted cryogenic coolant medium is the most powerful method in all machining characteristics as providing better tribological properties. The paper proposes a novel approach for improved machinability performance of Cu-based hybrid composites with sustainable techniques.
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    Tool wear, surface roughness, cutting temperature and chips morphology evaluation of Al/TiN coated carbide cutting tools in milling of Cu-B-CrC based ceramic matrix composites
    (Elsevier, 2022) Usca, Usame Ali; Uzun, Mahir; Sap, Serhat; Kuntoglu, Mustafa; Giasin, Khaled; Pimenov, Danil Yu; Wojciechowski, Szymon
    Ceramics-based composites are a special class of materials carrying combined properties that belongs to alloys and metals according to market demands. This makes composites completely different and paves the way for new applications that requires the utmost properties. Machining of such composites is of great importance to finalize the fabrication process with improved part quality; however, the process implies several challenges due to the complexity of the cutting processes and random material structure. The current study aims to examine the machinability characteristics when milling novel material, Cu-B-CrC composites using Al/TiN coated carbide tools. Further, the influence of machining parameters along with the different weight ratios of the powders amounts used to fabricate the machined reinforced samples on output parameters namely surface roughness, tool wear, chip morphology and cutting temperatures was investigated. One of the key findings of the study is the dominant effect of reinforcement ratio (Cu, B, CrC) on machinability, which showed that 5% additive (2% B, 3% CrC) provides improved properties such as surface roughness, tool wear and cutting temperature. Cutting speed alterations play an important role in the machinability characteristics, i.e., increasing value increases flank wear and cutting temperatures and reduces surface roughness. Increasing feed rate in-creases the surface roughness meanwhile its effect shows changing behavior on the flank wear and cutting temperatures according to cutting speed and reinforcement ratio.(c) 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
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    Tribological Aspects, Optimization and Analysis of Cu-B-CrC Composites Fabricated by Powder Metallurgy
    (Mdpi, 2021) Usca, usame Ali; Uzun, Mahir; Kuntoglu, Mustafa; Sap, Serhat; Giasin, Khaled; Pimenov, Danil Yurievich
    Tribological properties of engineering components are a key issue due to their effect on the operational performance factors such as wear, surface characteristics, service life and in situ behavior. Thus, for better component quality, process parameters have major importance, especially for metal matrix composites (MMCs), which are a special class of materials used in a wide range of engineering applications including but not limited to structural, automotive and aeronautics. This paper deals with the tribological behavior of Cu-B-CrC composites (Cu-main matrix, B-CrC-reinforcement by 0, 2.5, 5 and 7.5 wt.%). The tribological characteristics investigated in this study are the coefficient of friction, wear rate and weight loss. For this purpose, four levels of sliding distance (1000, 1500, 2000 and 2500 m) and four levels of applied load (10, 15, 20 and 25 N) were used. In addition, two levels of sliding velocity (1 and 1.5 m/s), two levels of sintering time (1 and 2 h) and two sintering temperatures (1000 and 1050 degrees C) were used. Taguchi's L-16 orthogonal array was used to statistically analyze the aforementioned input parameters and to determine their best levels which give the desired values for the analyzed tribological characteristics. The results were analyzed by statistical analysis, optimization and 3D surface plots. Accordingly, it was determined that the most effective factor for wear rate, weight loss and friction coefficients is the contribution rate. According to signal-to-noise ratios, optimum solutions can be sorted as: the highest levels of parameters except for applied load and reinforcement ratio (2500 m, 10 N, 1.5 m/s, 2 h, 1050 degrees C and 0 wt.%) for wear rate, certain levels of all parameters (1000 m, 10 N, 1.5 m/s, 2 h, 1050 degrees C and 2.5 wt.%) for weight loss and 1000 m, 15 N, 1 m/s, 1 h, 1000 degrees C and 0 wt.% for the coefficient of friction. The comprehensive analysis of findings has practical significance and provides valuable information for a composite material from the production phase to the actual working conditions.