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Öğe AISI 1050 Malzemenin Delinmesinde Delme Parametrelerinin Delik Kalitesi Üzerindeki Etkisinin Çoklu Regresyon Metoduyla Modellenmesi(Makine Teknolojileri Elektronik Dergisi, 2011) Meral, Güven; Dilipak, Hakan; Sarıkaya, MuratBu çalısmada, delme islemlerinde önemli yere sahip olan delik çapındaki değisim, dairesellikten sapma ve silindiriklikten sapma, deneysel olarak arastırılmıs ve delme parametrelerinin delik kalitesi üzerindeki etki regresyon metoduyla ortaya konulmustur. Deneylerde 6, 8, 10 mm çaplarında kaplamasız ve PVD metodu ile TiAlN kaplanmıs kaplamalı HSS matkaplar kullanılmıstır. Deneyler üç farklı kesme hızı ( farklı ilerleme (0,05, 0,1, 0,15 mm/dev) değerlerinde kuru delme sartlarında CNC dik isleme merkezinde yapılmıstır. Deney sonuçları ikinci dereceden çoklu regresyon analizi ile SPSS 15 yazılımı kullanılarak değerlendirilmistir. Sonuç olarak hc (çaptan sapma), hd (dairesellikten sapma) ve küçük kareler yöntemi kullanılarak elde edilen korelasyon katsayısının karesi (R²) değerleri sırasıyla %88,3, %76 bulunmustur. Delik kalitesine etki eden parametrelerin belirlenerek, matematiksel bir formül elde edilmesi ve tahmin sonuçlarının ortaya konulmasında olduğu tespit edilmistir. Ayrıca, delik kalitesi parametreleri içerisinden delik çapındaki değisimin regresyon modeliyle hesaplanmasında, en yüksek R olustuğu görülmüstür.Öğe AISI 1050 Malzemenin Delinmesinde Ilerleme Kuvvetleri ve Yüzey Pürüzlülügünün Regresyon Analiziyle Modellenmesi(Tübav Bilim Dergisi, 2011) Meral, Güven; Dilipak, Hakan; Sarıkaya, MuratBu çalışmada, deneyler sonucunda elde edilen ilerleme kuvvetleri ve yüzey pürüzlülüklerinin, matkap türü (kaplamalıkaplamasız), matkap çapı, ilerleme değeri ve kesme hızı gibi deney parametrelerine bağlı olarak, lineer regresyon, ikinci dereceden regresyon ve üstel regresyon metotları ile modellemesi yapılmıştır. Deneylerde, endüstriyel uygulamalarda yaygın olarak kullanılan ve işlenebilirlik özellikleri iyi bilinen AISI 1050 çelik malzeme referans alınmıştır. Deneylerde, 6, 8, 10 mm çaplarında kaplamasız ve PVD metodu ile TiAlN kaplanmış kaplamalı HSS matkaplar kullanılmıştır. Deneyler, üç farklı kesme hızı (20, 30, 40 m/dak) ve üç farklı ilerleme (0.05, 0.1, 0.15 mm/dev) değerinde kuru delme şartlarında CNC dik işleme merkezinde yapılmıştır. İlerleme hızı (f), kesme hızı (Vc), matkap çapı (d) ve matkap türünün (q) yüzey pürüzlülüğü (Ra) ve ilerleme kuvvetleri (fz) üzerindeki etkisini belirlemek için, ANOVA (Varyans Analizi) kullanılmıştır. Sonuç olarak, uygulanan regresyon modelinin tümüne bakıldığında, kesme parametrelerine karşılık gelen ilerleme kuvvetinin ve yüzey pürüzlülüğün modellenmesinde kullanılacak en uygun metodun, ikinci dereceden regresyon modeli olduğu görülmüştür. İkinci dereceden regresyon modelinden elde edilen sonuçlara göre, ilerleme kuvvetinin kaplamalı matkaplara göre kaplamasız matkaplarda daha fazla oluştuğu, ayrıca artan ilerleme hızı ve matkap çapı ile beraber daha da arttığı gözlenmiştir. Yüzey pürüzlülüğü modelinden elde edilen sonuçlara göre, delik üzerinde oluşan yüzey pürüzlülüğü, kaplamasız matkaplara göre kaplamalı matkaplarda daha az oluşmuştur. Yüzey pürüzlülüğü, ilerleme hızı ve matkap çapı artışıyla doğru orantılı olarak artmış ve kesme kuvveti artışı ile ters orantılı bir şekilde azalmıştır.Öğe DEEP MICRO-HOLE DRILLING FOR HADFIELD STEEL BY ELECTRO-DISCHARGE MACHINING (EDM)(Inst Za Kovinske Materiale I In Tehnologie, 2015) Yilmaz, Volkan; Sarikaya, Murat; Dilipak, HakanIn this study, a new system for drilling deep micro-holes was designed for Hadfield steel (which is difficult to process with classical methods) with the electro-discharge-machining method (EDM) and the system was experimentally examined. The tests were carried out at three different discharge currents (6, 12 and 24) A, three different electrode-tool rotational speeds (200, 400 and 600) r/min, three different dielectric spray pressures (40, 80 and 120) bar, a constant pulse duration (12 mu s) and a constant pulse interval (3 mu s). After the tests the effects of the processing parameters on the basic performance outputs (the material removal rate -MRR), the electrode wear rate (EWR) and the relative wear (RW)) were investigated. Additionally, an analysis of variance (ANOVA) was also applied to identify the most significant factor. Optimum operating parameters were determined using the desirability-function analysis through the response surface methodology (RSM). It was found that the most effective variable affecting the MRR, EWR and RW was the discharge current. The discharge current was found to be the most significant control factor influencing the performance of the machining process.Öğe Delik Delme Uygulamalarında Delik Kalitesinin Taguchi Yöntemiyle Optimizasyonu(Mühendis ve Makina Dergisi, 2011) Meral, Güven; Sarıkaya, Murat; Dilipak, Hakan[Abstract Not Available]Öğe Delme Parametrelerinin Taguchi Yöntemiyle Optimizasyonu(Erciyes Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 2011) Meral, Güven; Sarıkaya, Murat; Dilipak, HakanBu çalışmada, delik delme işlemlerinde kaplamalı ve kaplamasız matkapların, kesme parametrelerine bağlı olarak performansları araştırılmış ve optimum işleme şartları tespit edilmiştir. Deneyler Taguchi L9 orthogonal (dik) düzlemine göre yapılarak deney sonuçlarının değerlendirilmesinde sinyal/gürültü (S/N) oranı esas alınmıştır. Minitab 15 yazılımı yardımıyla Taguchi tekniği kullanılarak optimum kesme kuvveti ve yüzey pürüzlülüğü değerlerini veren kontrol faktörleri belirlenmiştir. Kontrol faktörlerinin sonuçlara etkisi Varyans analizi (ANOVA) yardımıyla bulunmuştur. Son olarak doğrulama deneyleri yapılmış ve optimizasyonun başarıyla uygulandığı tespit edilmiştir.Öğe Frezeleme islemlerinde kesme kuvveti, titresim ve yüzey pürüzlülügü sonuçlarinin modellenmesi(Erciyes Üniversitesi, 2014) Yilmaz, Volkan; Dilipak, Hakan; Sarikaya, Murat; Yilmaz, Ceren Yaman; Özdemir, MustafaBu çalismada, frezeleme islemlerinde kesme parametrelerinin kesme kuvveti, titresim ivmesi ve yüzey pürüzlülügü üzerindeki etkisi çoklu regresyon analiziyle arastirilmistir. Deneylerde isleme parametreleri olarak 132, 220, 308 m/min kesme hizi, 0,05, 0,1, 0,15, 0,2 mm/tooth ilerleme, 1, 1,5 mm kesme derinligi ve 1, 2, 4 adet sayilardaki kesici uç kullanilmistir. Bu isleme parametreleri ile 100x50x20 mm ebatlarinda AISI 1050 deney malzemesi üzerinden talas kaldirilmistir. Deney sonuçlarina etki eden parametrelerin oranlari Minitab 15.0 yazilimi kullanilarak çoklu regresyon analiziyle ANOVA (Varyans Analizi) tablolari olusturularak bulunmustur. Ayrica ara degerlerin hesaplanmasinda sonuçlar için üç ayri matematiksel formül gelistirilmis ve tahminsel sonuçlar elde dilmistir.Öğe Frezeleme islemlerinde kesme kuvveti, titresim ve yüzey pürüzlülügü sonuçlarının modellenmesi(Erciyes Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 2014) Yılmaz, Volkan; Dilipak, Hakan; Sarıkaya, Murat; Yılmaz, Ceren Yaman; Özdemir, MustafaBu çalışmada, frezeleme işlemlerinde kesme parametrelerinin kesme kuvveti, titreşim ivmesi ve yüzey pürüzlülüğü üzerindeki etkisi çoklu regresyon analiziyle araştırılmıştır. Deneylerde işleme parametreleri olarak 132, 220, 308 m/min kesme hızı, 0,05, 0,1, 0,15, 0,2 mm/tooth ilerleme, 1, 1,5 mm kesme derinliği ve 1, 2, 4 adet sayılardaki kesici uç kullanılmıştır. Bu işleme parametreleri ile 100x50x20 mm ebatlarında AISI 1050 deney malzemesi üzerinden talaş kaldırılmıştır. Deney sonuçlarına etki eden parametrelerin oranları Minitab 15.0 yazılımı kullanılarak çoklu regresyon analiziyle ANOVA (Varyans Analizi) tabloları oluşturularak bulunmuştur. Ayrıca ara değerlerin hesaplanmasında sonuçlar için üç ayrı matematiksel formül geliştirilmiş ve tahminsel sonuçlar elde dilmiştir.Öğe Frezeleme Islemlerinde Titresimi ve Yüzey Pürüzlülügünü Etkileyen Parametrelerin Optimizasyonu(SDÜ Teknik Bilimler Dergisi, 2014) Yılmaz, Volkan; Dilipak, Hakan; Sarıkaya, Murat; Yılmaz, Ceren Yaman; Meral, GüvenBu çalışmada, frezeleme işlemlerinde kesme parametrelerinin titreşim ivme seviyesi ve yüzey kalitesi üzerindeki etkileri araştırılmış ve optimum işleme parametreleri tespit edilmiştir. Deneylerde Taguchi tasarım tekniği kullanılmış ve 132, 220, 308 mm/min kesme hızı, 0,05, 0,1, 0,2 mm/tooth ilerleme, 1, 1,5 mm kesme derinliği ve 1, 2, 4 adet uç sayısı kontrol faktörleri olarak belirlenmiştir. İşleme parametrelerine uygun olarak deneylerde Taguchi L18 (2¹x3³) orthogonal dizi seçilmiştir. Deney sonuçları değerlendirilirken Minitab 15 yazılımı yardımıyla sinyal/gürültü (S/N) oranı esas alınmış ve optimum titreşim ivmesi seviyesi ve yüzey pürüzlülüğü değerlerini veren kontrol faktörleri belirlenmiştir. Kontrol faktörlerinin sonuçlara etkisi varyans analizi (ANOVA) yardımıyla bulunmuştur. Sonuç olarak titreşim ivme seviyesi ve yüzey pürüzlülüğünün en fazla ilerleme değerinden etkilendiği tespit edilmiştir.Öğe Investigation of deep-drilled micro-hole profiles in Hadfield steel(Carl Hanser Verlag, 2016) Yilmaz, Volkan; Sarikaya, Murat; Dilipak, HakanHadfield steel, due to its high manganese content, is difficult to drill and work-hardens very quickly. In this study, Hadfield steel material was drilled with micro-size deep holes using the electrical discharge machining (EDM) technique, and hole diameter values were examined for specific machining parameters. Experiments were carried out with three different discharge currents (6, 12 and 24 A), three different electrode rotational speeds (200, 400 and 600 rev x min(-1)), three different pulse durations (12, 50 and 100 mu s), a fixed dielectric spray pressure (40 bars) and a fixed pulse interval (3 mu s). It was determined that the hole profiles obtained following the tests are directly related to the machining parameters, and that the resulting average overcut (AOC) and taper (Tp) values increased with discharge current, electrode rotational speed and pulse duration. Analysis of variance (ANOVA) conducted demonstrates that pulse duration is the dominant parameter affecting AOC, whereas pulse duration has the highest effect on Tp. When determination coefficients and normal probability plots were compared for the mathematical models obtained from analyses conducted for the prediction of test values, it was observed that the models obtained by quadratic regression analysis exhibited a better performance than the models produced by linear regression analysis.Öğe Matkap Uç ve Kanal Geometrisi Tasariminin Kesme Kuvvetleri Üzerindeki Etkilerinin Taguchi Yöntemiyle Analizi(Mus Alparslan Üniversitesi, 2017) Meral, Güven; Dilipak, Hakan; Sarikaya, Murat; Seker, UlviBuçalismada, iki adet özgün matkap kanal geometrisi tasarlanmis ve üretilmistir.Deneysel çalismalarda ticari olarak tedarik edilebilen en yaygin iki takimgeometrisi (Geometri 1, Geometri 2) ile gelistirilen özgün iki kanal geometrisi(Geometri 3, Geometri 4) performanslari test edilmistir. Takim geometrilerinindelik delme performansi üzerindeki etkilerini arastirmak ve ideal islemeparametrelerinin belirlemek için Taguchi deney tasarimi kullanilmistir. Anova analiziile giris parametrelerinin deney sonuçlari üzerindeki etkisi istatistikselolarak bulunmustur. Ayrica Taguchi’nin Sinyal/Gürültü (S/G) analizi, yardimiylaen iyi sonuç için kontrol faktörlerinin optimum seviyeleri belirlenmistir.Öğe Modeling and multi-response optimization of milling characteristics based on Taguchi and gray relational analysis(Sage Publications Ltd, 2016) Sarikaya, Murat; Yilmaz, Volkan; Dilipak, HakanThis article focuses on experimental investigation and effective approach to optimize the milling characteristics with mono and multiple response outputs such as vibration signals, cutting force, and surface roughness. To achieve this goal, experiments were designed based on Taguchi's L-18 (2(1)x3(3)) orthogonal array. During the milling of AISI 1050 steel, process performance indicators such as vibration signals (RMS), cutting force (Fx), and surface roughness (Ra) were measured. The effect of process parameters such as depth of cut, feed rate, cutting speed, and number of insert on RMS, Fx, and Ra were investigated and parameters were simultaneously optimized by taking into consideration the multi-response outputs using Taguchi-based gray relational analysis. Taguchi's signal-to-noise ratio was employed to obtain the best combination with smaller-the-better and larger-the-better approaches for mono- and multi-optimization, respectively. Analysis of variance was conducted to determine the importance of process parameters on responses. Mathematical models were created, namely, RMSpre, Ra-pre, and Fx(pre), using regression analysis. According to the multi-response optimization results, which were obtained from the largest signal-to-noise ratio of the gray relational grade, it was found out that the optimum combination was depth of cut of 1mm, feed rate of 0.05mm/rev, cutting speed of 308m/min, and number of insert of 1 to minimize simultaneously RMS, Fx, and Ra. It was obtained that the percentage improvement in gray relational grade with the multiple responses is 42.9%. It is clearly shown that the performance indicators are significantly improved using this approach in milling of AISI 1050 steel. Moreover, analysis of variance for gray relational grade proved that the feed rate is the most influential factor as the minimization of all responses is concurrently considered.Öğe Multi-objective optimization of surface roughness, thrust force, and torque produced by novel drill geometries using Taguchi-based GRA(Springer London Ltd, 2019) Meral, Guven; Sarikaya, Murat; Mia, Mozammel; Dilipak, Hakan; Seker, Ulvi; Gupta, Munish K.A significant part of today's chip removal processes are drilling holes. Many parameters such as cutting parameters, material, machine tool, and cutting tool, etc., in the hole-drilling process affect performance indicators such as surface roughness, tool wear, force, torque, energy consumption, and costs etc. While cutting parameters are easily planned by the operator during drilling, the selection and planning of the drill geometry are more difficult. In order to design and produce the new drill geometry, a wide time and engineering research are needed. In this study, the design and fabrication of new drill geometry were performed to improve the hole-drilling performance. The performance of the fabricated drills was judged with regard to surface roughness, thrust force, and drilling torque. In the performance tests, four different drill geometries, four different cutting speed levels, and four different feed rate levels were selected. Holes were drilled on AISI 4140 material. In addition, the optimization was performed in two phases. Firstly, the mono-optimization was carried by using Taguchi's S/N analysis in which each performance output was optimized separately. Secondly, the multi-objective optimization was employed by using Taguchi-based gray relational analysis (GRA). For the purpose of the study, two different drill geometries were designed and fabricated. Experimental results showed that the designed Geometry 4 is superior to other geometries (geometry 1, geometry 2, and geometry 3) in terms of thrust force and surface roughness. However, in terms of drilling torque, geometry 2 gives better results than other drill geometries. It was found that for all geometries, obtained surface roughness values are lower than the surface roughness values expected from a drilling operation and therefore surface qualities (between 1.2 and 2.4m) were satisfactory.Öğe Multi-response Optimization of Cutting Parameters for Hole Quality in Drilling of AISI 1050 Steel(Springer Heidelberg, 2015) Meral, Guven; Sarikaya, Murat; Dilipak, Hakan; Seker, UlviIn this study, the surface roughness, dimensional accuracy, and circular and cylindrical deviations characterizing the hole quality were investigated experimentally. AISI 1050 steel in experiments was chosen as reference material due to its extensive applications in many areas. Uncoated and TiAlN coated by physical vapor deposition (PVD) method HSS twist drills with different diameters were used. Experiments were conducted on a CNC vertical machining center under dry condition with different cutting speeds and feed rates. The hole depth was 17 mm to ensure L < 3D condition. After each experiment, hole properties such as surface roughness, dimensional accuracy, circular deviation, and axial misalignment between inlet and outlet holes (cylindrical deviation), all of those that show the hole quality, were measured, and the results were evaluated. In addition to experimental analysis, a statistical analysis was carried out to indicate the effects of drilling parameters on test results. Process parameters such as tool type, drill diameter, feed rate, and cutting speed were optimized with consideration of multiple performance characteristics using desirability functional analysis. As a result, coated tools compared with uncoated tools gave positive results for each evaluation criterion. As the most important parameter on surface roughness (Ra) was drill diameter, the most effective parameter on dimensional accuracy, and circular and cylindrical deviations was cutting speed for both uncoated and coated tools except from cylindrical deviation occurring in uncoated drill.Öğe Optimization of hole quality produced by novel drill geometries using the Taguchi S/N approach(Springer London Ltd, 2019) Meral, Guven; Sarikaya, Murat; Mia, Mozammel; Dilipak, Hakan; Seker, UlviReportedly, the drill geometry influences the drilling operation. In fact, the performance of the drill bit is strongly associated with productivity, thus with economy of production. Moreover, the typical performance indicators, i.e., deviation from diameter, cylindricity, perpendicularity, and concentricity, are altered by drill geometry. This fact stresses the need for a novel design of drills with further optimization of performance indicators of hole quality. In that perspective, herein, new drill geometries were designed and fabricated. Afterward, those drills were employed to create holes on AISI 4140 steel, and their performances were investigated and optimized to suggest cutting parameters of best interest. For performance tests, four different drill geometries, four different cutting speeds (90, 100, 110, 120m/min), and four different feeds (0.15, 0.20, 0.25, 0.30mm/rev) were practiced. To measure the performance of the drills, the quality of the drilled holes was studied in terms of the deviation from diameter, cylindricity, perpendicularity, and concentricity. During the experiment, geometry 3 that was developed as the original drill geometry exhibited poor chip evacuation. As such, geometry 4 was developed by considering these negativities, and it was found to demonstrate superior performance compared to other geometries in terms of hole quality. Furthermore, ANOVA revealed that the drill bit flute geometry is the most influential factor. Lastly, the Taguchi S/N approach disclosed that drilling with geometry 4 at the cutting speed of 90m/min and feed rate of 0.15mm/rev produced optimum machining performance.Öğe Optimization of Process Parameters for Surface Roughness and Tool Life in Face Milling using The Taguchi Analysis(Materiali in Tehnologije, 2015) Sarıkaya, Murat; Dilipak, Hakan; Gezgin, AkınIn this study, the Taguchi method, which is a powerful tool to design quality optimization, is used to find the optimum surface roughness and tool life in milling operations. An orthogonal array, a signal-to-noise (S/N) ratio, and an analysis of variance (ANOVA) are employed to investigate the tool life and the surface-roughness characteristics of AISI D3 steel. Accordingly, the lowest surface roughness and the highest tool life were estimated to be 0.436 ?m and 434.1 s, respectively and, finally, the Taguchi method allowed the optimization of the system for the verification of the tests. Further, ANOVA analysis was revealed that the number of cutter insert was the most important parameter influencing the surface roughness with a 75.27 %, and cutting speed was the most important parameter influencing the tool life with a 95 %.Öğe OPTIMIZATION OF THE PROCESS PARAMETERS FOR SURFACE ROUGHNESS AND TOOL LIFE IN FACE MILLING USING THE TAGUCHI ANALYSIS(Inst Za Kovinske Materiale I In Tehnologie, 2015) Sarikaya, Murat; Dilipak, Hakan; Gezgin, AkinIn this study, the Taguchi method, which is a powerful tool to design quality optimization, is used to find the optimum surface roughness and tool life in milling operations. An orthogonal array, a signal-to-noise (S/N) ratio, and an analysis of variance (ANOVA) are employed to investigate the tool life and the surface-roughness characteristics of AISI D3 steel. Accordingly, the lowest surface roughness and the highest tool life were estimated to be 0.436 mu m and 434.1 s, respectively and, finally, the Taguchi method allowed the optimization of the system for the verification of the tests. Further, ANOVA analysis was revealed that the number of cutter insert was the most important parameter influencing the surface roughness with a 75.27 %, and cutting speed was the most important parameter influencing the tool life with a 95 %.Öğe Optimization of the wear behavior of uncoated, TiN and AlTiN coated cold work tool steel 1.2379 using response surface methodology(Carl Hanser Verlag, 2016) Bulbul, Ali Emrah; Dilipak, Hakan; Sarikaya, Murat; Yilmaz, VolkanIn this study, the wear behavior of uncoated, TiN and AlTiN coated cold work tool steel 1.2379 which is widely used in the mold industry was investigated experimentally. Heat treatment was applied to the specimens, then TiN and AlTiN PVD coating process was performed. The wear tests were carried out at 0.5 m x s(-1) sliding speed, 5, 10 and 15 N loads and 120 m sliding distance by using reciprocating abrasion device. The microhardness was measured and metallographic tests of the samples were investigated by SEM and EDS analysis. In order to examine the effect of process parameters on wear results, a statistical method such as analysis of variance (ANOVA) was employed. A mathematical model was created by using regression analysis based on both linear model and quadratic model for predicted wear value. Process parameters were optimized using response surface methodology with desirability function analysis. It is observed that the uncoated specimens worn approximately two times more than AlTiN coated and one time more than TiN coated. In the SEM images and EDS analysis, it is seen that the coating is spread uniformly on the materials.
