The Relationship of Burr Height and Blanking Force with Clearance in the Blanking Process of AA5754 Aluminium Alloy

The effect of clearance and sheet thickness in the AA5754 sheet material blanking process on the burr formation and blanking force was examined experimentally. Measurements of the burr height and blanking force were performed in a modular die with six different clearance values (8 %, 10 %, 12 %, 14 %, 16 % and 18 %) by applying the blanking process to the AA5754 sheet metal of 1 mm and 2 mm in thickness. The influence rate of parameters affecting the burr height, the blanking force, and the mathematical relationship between them were identified by using the analysis of variance (ANOVA) and the regression analysis. Thus, it was determined that the burr formation increased with increased clearance and that the blanking force was not affected in the same proportion. In addition, it was found that the sheet thickness and clearance affected the burr formation at rates of 23.24 % and 76.15 %, respectively; on the other hand, the sheet thickness and clearance affected the blanking force at rates of 99.72 % and 0.24 %, respectively

Statistical Evaluation of the Influence of Temperature and Surface Roughness on Aluminium Sheet Metal Forming

The influences of temperature and surface roughness on the forming of the AA3003-H111 aluminium alloy sheet material have been investigated by using the finite element method. For this purpose, material cards have been firstly created based on the sheet material behaviour at different deformation temperatures. As a result of the forming analyses performed at different temperature values and surface roughness values, it has been determined that the increase in the surface roughness reduces the amount of thinning while it increases the amount of forming force and the springback. It has also been determined that there is a slight increase in the amount of thinning, while the temperature rise reduces the amount of forming force and the springback. In addition, the influence levels of temperature and surface roughness have been determined by statistical analyses

Evaluation of the Effects of Local Heating on Springback Behaviour for AHSS Docol 1400 Sheet Metal

In this study, the impacts of the heating temperature and bending angle on springback were experimentally examined in the V-bending of Docol 1400 steel sheets. The bending angle (30°, 60°, 90° and 120°) and the temperature (Room Temperature-RT, 200°C, 300°C, 400°C, 500°C, 600°C) of the bending zone were determined as the variable experimental parameters. The springback was measured using a coordinate measuring machine (CMM). The springback was observed to decrease by 7.7% on average between RT and 200 ºC, to increase by 8% between 200 ºC and 300 ºC and by 18% between 300 ºC and 600 ºC. The material data used in the analyses were attained from the tensile test results conducted at different temperatures. The analysis shows that the springback values decreased linearly at elevated temperatures. It was seen that the mechanical properties of the material decreased within the temperature range of RT to 600ºC in the heated bending zone

EXPERIMENTAL INVESTIGATION OF THE PARAMETERS IN DEEP DRAWING DIES and ESTIMATION WITH FUZZY LOGIC

Bu çalışmada; derin çekme kalıplarında çekmeyi etkileyen parametreler deneysel olarak incelenmiştir. Deneysel çalışmalarda, değişik çekme parametreleri kullanılarak, silindirik ve kare olmak üzere iki farklı geometride derin çekme işlemleri gerçekleştirilmiştir. Deneysel çalışmalar, alüminyum, DKP ve pirinç sac malzemelerde uygulanmıştır. Derin çekme sırasında oluşan çekme kuvvetleri, çekme ekseni üzerine yerleştirilen Baykon yük hücresi yardımıyla ölçülmüştür. Kalıp kavisi, zımba kavisi, çekme hızı, çekme boşluğu ve sac malzeme kalınlığı parametrelerinin çekme işlemine etkileri incelenmiştir. Bu parametrelere bağlı olarak deney numunelerinde oluşan kırışıklık, yırtılma,sac kalınlığı incelmesi ve çekme kuvvetleri incelenmiştir. Sac malzemesinin ve çekme parametrelerinin, sac malzemelerdeki kırışıklığı, yırtılmayı ve miktarını,sac kalınlığında incelmeyi ve çekilebilirlik oranlarını doğrudan etkilediği görülmüştür. Deneysel numuneler aynı çekme parametreleri kullanarak, sonlu elemanlar metoduna dayalı çözüm yapan DYNAFORM ve AUTOFORM paket programları kullanılarak da analiz edilmiştir. Deneysel çalışma sonuçları ile analiz sonuçlarının çok yakın değerlerde olduğu görülmüştür. Deneysel çalışmalardan elde edilen verilerden yararlanılarak, deney yapılmayan parametre değerlerinin çekilebilirlik değerlerine etkilerini tahmin etmek amacıyla bir bulanık mantık modeli geliştirilmiştir. Elde edilen sonuçlar pratik kullanımlar için literatüre kazandırılmıştır.In this study, drawing parameters in the deep drawing dies were experimentally examined. In the experimental studies, deep drawing process has been carried out on the different drawing parameters and on the different profiles as cylindrical and square. Experiments were carried out using Brass, DKP and Aluminium sheet metal materials. The drawing forces occurred during sheet metal deep drawing were measured by Baykon Load Cell. Effects of drawing parameters as die radius, punch radius, drawing speed, die clearance and sheet metal thickness on the drawing process were experimentally researched. Wrinkling, splitting, thinning of sheet metal thickness and the drawing force occurred during sheet metal deep drawing was investigated on the samples. It was show that the drawing parameters directly affected wrinkling, splitting, lower of sheet metal thickness and drawability rate. The samples with same drawing parameters were analysed on the finite element method by means of DYNAFORM and AUTOFORM software. It was seen that the results of the experimental study and the result of analysis are very close. According to the experimental results a fuzzy logic model was improved to estimate for effect of drawing parameters. Results introduce to literature for practically use

DP600 Sac Malzemenin Delik Flanşlama İşleminde Zımba Formunun Etkileri

maummfdDelik flanşlama, sac parçaların mukavemetinin artmasını sağlayan fonksiyonel bir işlemdir. Bu işlem aynı zamanda konumlandırma ve sabitleme uygulamaları için de kullanılır. Delik flanşlama işlemi, sac malzeme cinsi, kalınlığı, flanş profili, zımba formu ve ön delik çapı gibi birçok parametreden etkilenmektedir. Yapılan bu çalışmada otomotiv sektöründe yaygın olarak kullanılan DP600 sac malzemenin flanşlanması işleminde zımba formu ve zımba çapının flans yüksekliği ve et kalınlığına etkisi analitik olarak incelenmiştir. Analiz çalışmalarında DEFORM 2D sonlu elemanlar yazılımı kullanılmıştır. Sac malzeme üzerinde yapılan kimyasal analiz ve çekme testi sonuçlarından elde edilen veriler analiz programına girdi teşkil etmiştir. Analizlerde küresel, konik ve köşe kavisli olmak üzere üç farklı zımba formu kullanılmıştır. Delik çapı 10 mm ve zımba çapları 12, 14 ve 16 mm olarak alınmıştır. Analizler sonucunda malzemenin şekillendirilmesinde zımba formu ve zımba çapının önemli etkiye sahip olduğu, maksimum incelme ve flanş yüksekliğinin zımba formu ile doğrudan alakalı olduğu görülmüştür.102833

Effect of Abrasive Type on the Surface Roughness and MRR in MAF of AISI 304 Steel

In this study, the effects of experimental parameters on average surface roughness and material removal rate (MRR) were experimentally investigated by machining of AISI 304 stainless steel plates by magnetic abrasive finishing (MAF) method. In the study in which three different abrasive types were used (Al2O3, B4C, SiC), the abrasive grain size was changed in two different levels (50 and 80&amp;#x3BC;" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;">μm), while the machining time was changed in three different levels (30, 45, 60" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;">min). Surface roughness values of finished surfaces were measured by using three-dimensional (3D) optical surface profilometer and surface topographies were created. MRRs were measured with the help of precision scales. The abrasive particles’ condition before and after the MAF process was examined and compared using a scanning electron microscope. As a result of the study, the surface roughness values of plates were reduced from 0.106" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;">&amp;#x3BC;" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;">μm to 0.028" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;">&amp;#x3BC;" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;">μm. It was determined that the best parameters in terms of average surface roughness were 60" role="presentation" style="display: inline; line-height: normal; word-spacing: normal; overflow-wrap: normal; white-space: nowrap; float: none; direction: ltr; max-width: none; max-height: none; min-width: 0px; min-height: 0px; border: 0px; padding: 0px; margin: 0px; position: relative;"><span style="box-sizing: content-box; transition: none 0s ease 0s; display: inline-block; position: static; border-width: 0px; border-top-style