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Öğe A new approach for postprocessor design(2005) Er, Ali Osman; Aslan, ErsanNowadays, it can be possible that the parts which have complex shapes can be manufactured easily with the improvements on the Computer Integrated Manufacturing (CIM). Cutter Location Data (CLDATA) can be created with a Computer Aided Manufacturing (CAM) software, then the integration with the CNC machines is made by the postprocessors. In this study our target was making a flexible postprocessor which can work for all described control unites. Using datas taken from a CAD-CAM software's Design and Manufacturing Modules as specifications of solid model and CLDATA, the output of machining operations and some part programs (Mazak, Fanuc and Sinumerik) were taken out. Taken output of part programs were compared with programs which were used in real production unites.Öğe Bilyalı rulman hasarlarının titreşim analizi yöntemiyle incelenmesi(2006) Arslan, Hakan; Aslan, Ersan; Aktürk, NizamiBu çalışmada, titreşim yöntemi kullanılarak radyal bilyalı rulmanlardaki bölgesel yüzey kusurları deneysel olarak incelenmiştir. Bu amaçla bilyalı rulman elemanları (iç bilezik ve dış bilezik) çalışma yüzeylerinde yapay bölgesel kusurlar oluşturulmuş ve radyal yöndeki mil titreşimleri kaydedilmiştir. Sistem için teorik bir model oluşturulmuş ve bu modele göre sağlam ve kusurlu rulmanları analiz edebilen bir simülasyon programı geliştirilmiştir. Bu simülasyon programı, deney setinde kullanılan mil ve rulman boyutları girilerek çalıştırılmış ve farklı mil hızları için milin titreşim spektrumları elde edilmiştir. Simülasyon programından elde edilen teorik sonuçlarla deneysel sonuçlar karşılaştırıldığında göreceli olarak bir uyum gözlemlenmiştir.Öğe Data extraction from CAD model for rotational parts to be machined at turning centres(Scientific and Technical Research Council of Turkey, Ankara, Turkey, 1999) Aslan, Ersan; Şeker, Ulvi; Alpdemir, NedimAmong the most important data produced and stored is product data. CAD data forms one of many contributors to product data. Although in most circumstances CAD data can be processed within the CIM environment by integrated software components to produce information like manufacturing data, assembly data, etc., there are a significant number of cases where an external CAD resource needs to be processed. An external CAD resource comes in the form of a neutral file format such as DXF, IGES, STEP, etc. Extracting the necessary information from an exchange file to generate manufacturing parameters thus becomes an important task. In this paper we present the results of our research efforts which were intended to extract information from the defacto industry standard DXF files to determine features existing on rotational parts to be machined on turning centres, and later utilise this information in the context of a software package implemented to develop a post-processing expert system. The feature extraction module presented in this paper, forms part of that expert system, which is named ASALUS (Aslan, 1995) and is illustrated in Figure 1. ASALUS is designed to manage the life cycle of rotational parts from the design all the way to the production by performing process planning using a generative approach and applying post-processing for two different CNC lathes.Among the most important data produced and stored is product data. CAD data forms one of many contributors to product data. Although in most circumstances CAD data can be processed within the CIM environment by integrated software components to produce information like manufacturing data, assembly data, etc., there are a significant number of cases where an external CAD resource needs to be processed. An external CAD resource comes in the form of a neutral file format such as DXF, IGES, STEP, etc. Extracting the necessary information from an exchange file to generate manufacturing parameters thus becomes an important task. In this paper we present the results of our research efforts which were intended to extract information from the defacto industry standard DXF files to determine features existing on rotational parts to be machined on turning centres, and later utilize this information in the context of a software package implemented to develop a post-processing expert system. The feature extraction module presented in this paper, forms part of that expert system, which is named ASALUS (Aslan, 1995) and is illustrated in Figure 1. ASALUS is designed to manage the life cycle of rotational parts from the design all the way to the production by performing process planning using a generative approach and applying post-processing for two different CNC lathes.Öğe Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al2O3+TiCN mixed ceramic tool(Elsevier Sci Ltd, 2007) Aslan, Ersan; Camuscu, Necip; Birgoren, BurakDue to their high hardness and wear resistance, Al2O3-based ceramics are one of the most suitable cutting tool materials for machining hardened steels. However, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. This necessitates a process optimization when machining hardened steels with Al2O3 based ceramic cutting tools. The present paper outlines an experimental study to achieve this by employing Taguchi techniques. Combined effects of three cutting parameters, namely cutting speed, feed rate and depth of cut on two performance measures, flank wear (VB) and surface roughness (R-a), were investigated employing an orthogonal array and the analysis of variance (ANOVA). Optimal cutting parameters for each performance measure were obtained; also the relationship between the parameters and the performance measures were determined using multiple linear regression. (c) 2006 Elsevier Ltd. All rights reserved.Öğe Experimental investigation of cutting tool performance in high speed cutting of hardened X210 Cr12 cold-work tool steel (62 HRC)(Elsevier Ltd, 2005) Aslan, ErsanThis study explored the performance and wear behaviour of different cutting tools in end milling of X210 Cr12 cold-work tool steel hardened to 62 HRC. The purpose of the experiments reported in this paper is to investigate the wear of TiCN coated tungsten carbide, TiCN + TiAlN coated tungsten carbide, TiAlN coated cermet, mixed ceramic with Al2O3 + TiCN and cubic boron nitride (CBN) tools. Tool performance evaluation was based on the surface finish and tool flank wear. Tool flank wear was studied carefully through JSM 5600 (30 kW) scanning electron microscope. Surface roughness values were measured by Mitutoyo Metusurf 310 equipment. CBN tool exhibited the best cutting performance in terms of both flank wear and surface finish. The highest volume of metal removal was obtained with CBN tool. © 2004 Elsevier Ltd. All rights reserved.Öğe Experimental investigation of the effect of cutting tool rake angle on main cutting force(Elsevier Science Sa, 2005) Günay, Mustafa; Korkut, İhsan; Aslan, Ersan; Şeker, UlviThis paper presents a study of the influence of tool rake angle on the main cutting force for machining rotational parts by sharp cutting tools. A special dynamometer was designed and produced to measure the forces for this purpose. Two strain gages were placed in the proper position onto machine tool and cutting tool. Replacements of the tool caused by cutting forces were sensed by these proper placements. The well-known material, AISI 1040, was used in the experiments. Main cutting force (F-c) was measured for eight different rake angles ranging from negative to positive and five cutting speeds while depth of cut and feed rate remaining constant. As a result of experimental evaluation, cutting force decreasing trend was observed due to rake angle increasing in positive. (c) 2004 Elsevier B.V. All rights reserved.Öğe Experimental robust optimal machining of hardened AISI 420 stainless steel with Al2O3+TiCN mixed ceramic tool(Sage Publications Ltd, 2011) Acar, Erdem; Camuscu, N.; Er, Ali Osman; Aslan, ErsanThe high hardness and wear resistance levels of Alumina (Al2O3)-based ceramics make them excellent choices for incorporation into cutting tools that can be used to machine hardened steels. However, their poor fracture behaviour usually leads to catastrophic failures when they are used in these machining tasks. Thus, there is a need for an investigation that probes the effect of cutting parameters on the machining of hardened steels with Al2O3-based ceramic cutting tools and isolates a set of optimal values of cutting parameters. This paper is such a study. An experimental study that is guided by Taguchi's techniques is performed to analyse the effects of three cutting parameters: cutting speed; feed rate; and depth of cut on two performance measures, flank wear and surface roughness. The robust optimal cutting parameters for each performance measure are reported.Öğe Farklı sertliklerdeki X210CR12 soğuk iş takım çeliğinin parmak frezeleme işleminde,kaplamalı sinterlenmiş karbür ve kaplamalı sermet kesici takımların performanslarının karşılaştırılması(2005) Camuşcu, Necip; Aslan, ErsanSon yıllarda talaşlı üretim uygulamalarındaki genel yaklaşım, iş parçalarının son sertliklerinde talaş kaldırmaya tabi tutulmalarıdır. Bununla tezgah, kesici, iş gücü ve enerjiden kazançların elde edilmesi hedeflenmektedir. Bu çalışmada, 35 HRC ve 62 HRC'ye sertleştirilmiş X210CR12 çeliğinin farklı kesici takımlarla işlenmesinde aşınma davranışları ve performansları incelenmiştir. Kesici takım olarak kimyasal buhar çökertme yöntemiyle TiCN, fiziksel buhar çökertme yöntemi ile TiCNTiAlN kaplamalı sinterlenmiş karbür takımlar ve fiziksel buhar çökertme ile TiAlN kaplamalı sermet kesici takımlar kullanılmıştır. Kesici performans değerlendirmesi, işlenmiş parçaların yüzey kalitesine ve kesici takımın yanal yüzey aşınmasına göre yapılmıştır. TiCNTiAlN kaplamalı sinterlenmiş karbür ve TiAlN kaplamalı sermet kesici takımlar hem yanal yüzey aşınması hem de işlenmiş parçanın yüzey kalitesi açısından TiCN kaplamalı sinterlenmiş karbür takıma göre daha iyi performans göstermiştir.Öğe A new approach for postprocessor design(2005) Er, Ali Osman; Aslan, ErsanNowadays, it can be possible that the parts which have complex shapes can be manufactured easily with the improvements on the Computer Integrated Manufacturing (CIM). Cutter Location Data (CLDATA) can be created with a Computer Aided Manufacturing (CAM) software, then the integration with the CNC machines is made by the postprocessors. In this study our target was making a flexible postprocessor which can work for all described control unites. Using datas taken from a CAD-CAM software's Design and Manufacturing Modules as specifications of solid model and CLDATA, the output of machining operations and some part programs (Mazak, Fanuc and Sinumerik) were taken out. Taken output of part programs were compared with programs which were used in real production unites.Öğe A numerical model to determine temperature distribution in orthogonal metal cutting(Elsevier Science Sa, 2006) Doğu, Yahya; Aslan, Ersan; Camuscu, NecipIn this study, a thermal analysis model is developed to determine temperature distribution in orthogonal metal cutting using finite elements method. The model calculates the temperature distribution as a function of heat generation. The heat generation was introduced in the primary deformation zone, the secondary deformation zone and along the sliding frictional zone at the tool-chip interface, as well. The location and shapes of these zones was determined based on the literature work done so far and the model results. The temperature dependency of material properties was included in the model. A series of thermal simulations have been performed, and the value and location of maximum temperature have been determined for various cutting conditions. The comparison of the simulations with earlier works gave promising trend for the presented model. The thermal aspects of metal cutting as a result of the model findings were discussed. (c) 2005 Elsevier B.V. All rights reserved.Öğe Process unification and frame preparation of machining parametres for rotational parts(2005) Aslan, ErsanGeleneksel veya bilgisayarlı tezgahların kullanıldığı her hangi bir metal işleme ünitesi, üretilecek parçanın prototipine, teknik çizimine veya bir veri tabanına ihtiyaç duyar. Geleneksel üretim ünitesindeki tasarım, işlem planlama ve üretimde karşılaşılan mödelleme, standart veri yapılarından bilgi çıkarımı ve tezgahlar için parça programı hazırlama gibi problemler operatör veya uzmanlar tarafından problemin oluşması anında çözümlenir. Üretim süresi içindeki uygulamaların bilgisayar desteği ile gerçekleştirildiği ortamlarda ise, muhtemel problemlerin çözümüne yönelik olarak alan uzmanının bilgi birikiminin her hangi bir şekilde bir veri tabanına kaydedilmesi gerekir. Bu bilgiler ürün döngüsünün ihtiyaç duyulan bir aşamasında gerekli oldukça kullanılmaktadır. Bu makalede, yatay işleme merkezlerinde üretilecek silindirik parçalardaki işleme özelliklerinin belirlenmesi için gerekli olan tasarım ve imalat bilgisini DXF veri yapısından çıkarmak için gerçekleştirilen araştırmanın sonuçları sunulmuştur. Ayrıca işlem çıkarımı ve tanımlaması, işlem birleştirme ve parçanın işlenmesi için gerekli olan işleme parametrelerini tanımlamak amacıyla çerçeve oluşumu tanıtılmıştır.Öğe PROCESS UNIFICATION AND FRAME PREPARATION OF MACHINING PARAMETRES FOR ROTATIONAL PARTS(Pamukkale Univ, 2005) Aslan, ErsanAny traditional or computerized metal removal process needs a prototype, a technical drawing and a database for production of a part. Design, process planning and manufacturing problems such as modeling, the necessity data extraction from standard data exchange formats, and part programme preparation for machine tools can be solved by the operators or experts as soon as possible while they occurred in the traditonal approach. In circumstances of the production efforts spent by the computer, all experiences of expert can be saved in a database for foresight of the possible problems. This data can be used at any stage in the product cycle. In this paper, it is presented the results of research efforts which aimed to extract information from the defacto industry standard DXF files to determine features existing on rotational parts to be machined on horizontal machining centers. After process extraction and definition, process unifications and frame preparation for machining parameters of the part are introduced.Öğe Öğe Tool Condition Monitoring in Turning Using Statistical Parameters of Vibration Signal(Int Inst Acoustics & Vibration, 2016) Arslan, Hakan; Er, Ali Osman; Orhan, Sadettin; Aslan, ErsanIn this study, the relationship between vibration and tool wear is investigated during high-speed dry turning by using statistical parameters. It is aimed to show how tool wear and the work piece surface roughness changes with tool vibration signals. For this purpose, a series of experiments were conducted in a CNC lathe. An indexable CBN tool and a 16MnCr5 tool steel that was hardened to 63 HRC were both used as material twins in the experiments. The vibration was measured only in the machining direction using an acceleration sensor assembled on a machinery analyzer since this direction has more dominant signals than the other two directions. In addition, tool wear and work piece surface roughness are measured at different cutting time intervals where the cutting speed, radial depth of cut, and feed rate are kept constant. The vibration signals are evaluated using statistical analysis. The statistical parameters in this study are the Root Mean Square (RMS), Crest Factor, and Kurtosis values. When the flank wear increases, the Kurtosis value and RMS also increase, but the Crest factor exhibited irregular variations. It is concluded that these statistical parameters can be used in order to obtain information about tool wear and work piece surface roughness.Öğe Tool wear evaluation by vibration analysis during end milling of AISI D3 cold work tool steel with 35 HRC hardness(Elsevier Sci Ltd, 2007) Orhan, Sadettin; Er, Ali Osman; Camuscu, Necip; Aslan, ErsanIn this study, the relationship between vibration and tool wear was investigated during end milling. For this purpose, a series of experiment were conducted in a vertical milling machine. An indexable CBN insert and AISI D3 cold work tool steel hardened to 35 HRC were used as material twin in the experiments. The vibration was measured only in the machining direction, which has more dominant signals than in the other two directions. The measurements were taken by using an acceleration sensor assembled on a machinery analyzer. Tool wear was measured by a toolmaker's microscope. It was observed that there was an increase in vibration amplitude with increasing tool wears. This situation was evident especially by monitoring vibration of displacement type. It was also observed that the first three multiplies of tooth passing frequency (1 x, 2 x, 3 x) gave the best information about the tool wear. Results showed that there was no considerable increase in the vibration amplitude until a flank wear value of 160 mu m was reached, above which the vibration amplitude increased significantly. (C) 2006 Elsevier Ltd. All rights reserved.Öğe Yollardaki engellerde taşıtların dinamik davranışının iki serbestlik dereceli yarım taşıt modeli ile incelenmesi(2004) Yiğit, Osman; Aslan, ErsanBu çalışmada sabit hızla seyreden bir taşıtın ön tekerlerinin her ikisinin de yoldaki bir engelle aynı anda karşılaşması durumu incelenmiştir. Taşıt gövdesi rijit bir kütle olarak düşünülmüş, taşıtın yerle temasının doğrudan yaylar ve sönümleyiciler üzerinden olduğu kabulü yapılmıştır. Bir başka deyişle teker ve dingillerin kütleleri ile lastiklerin yaylanma ve sönüm özellikleri dikkate alınmamıştır. Bu durumda hareketin serbestlik derecesi taşıtın ağırlık merkezinin düşey doğrultudaki hareketi ve taşıt gövdesinin düşey düzlemde yapacağı açısal salınım hareketi olarak ortaya çıkmaktadır. Bu iki serbestlik derecesinde askı elemanlarının uyguladıkları kuvvetler dikkate alınarak, ikinci mertebeden iki adet diferansiyel denklem oluşturulmuş ve bu denklemler kritik bölgelerdeki yollara (okul önleri gibi) yerleştirilen özel bir engel durumu için çözülmüştür. Çözüm için sonlu fark yöntemi kullanılmış olup, hazırlanan program içinde yoldaki engel durumu adım adım girdi olarak verilmekte ve çıktı olarak taşıt ağırlık merkezinin düşey doğrultudaki yer değiştirmesi ve taşıt gövdesinin açısal yer değiştirmesi alınmaktadır. Daha sonra bu değerlerle ön ve arka dingil hizasında olan noktaların yer değiştirme değerleri hesaplanmaktadır.
