Browsing by Author "Simsek, Ulke"

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Citation - WoS: 2
Citation - Scopus: 2
An Investigation of the Performance of Equal Channel Angular Pressed Copper Electrodes in Electric Discharge Machining
(MDPI, 2025) Simsek, Ulke; Cogun, Can
This study examines the mechanical, thermal, and electrical properties of copper tool electrodes processed via Equal Channel Angular Pressing (ECAP), with a specific focus on their performance in Electrical Discharge Machining (EDM) applications. A novel Crystal Plasticity Finite Element Method (CPFEM) framework is employed to model anisotropic slip behavior and microscale deformation mechanisms. The primary objective is to elucidate how initial crystallographic orientation influences hardness, thermal conductivity, and electrical conductivity. Simulations are performed on single-crystal copper for three representative Face Centered Cubic (FCC) orientations. Using an explicit CPFEM model, the study examines texture evolution and deformation heterogeneity during the ECAP process of single-crystal copper. The results indicate that the <100> single-crystal orientation exhibits the highest Taylor factor and the most homogeneous distribution of plastic equivalent strain (PEEQ), suggesting enhanced resistance to plastic flow. In contrast, the <111> single-crystal orientation displays localized deformation and reduced hardening. A decreasing Taylor factor correlates with more uniform slip, which improves both electrical and thermal conductivity, as well as machinability, by minimizing dislocation-related resistance. These findings make a novel contribution to the field by highlighting the critical role of crystallographic orientation in governing slip activity and deformation pathways, which directly impact thermal wear resistance and the fabrication efficiency of ECAP-processed copper electrodes in EDM.
Citation - WoS: 17
Citation - Scopus: 18
Effects of Electrolytic Copper and Copper Alloy Electrodes on Machining Performance in Electrical Discharge Machining (Edm)
(Taylor & Francis inc, 2022) Esen, Ziya; Simsek, Ulke; Cogun, Can
The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal rate (MRR), low electrode wear rate (EWR), and relative wear (RW = MRR/EWR). In this study, the EDM performance outputs, namely, MRR and RW were experimentally investigated for electrolytic copper, CuCr1Zr (with and without aging treatment) and CuCo2Be alloy electrode materials for varying machining parameters. The performance outputs were affected by the electrode material and the applied aging treatment. The aged CuCr1Zr alloy electrodes had higher electrical conductivity and better machining performance than the as-received alloy. The CuCo2Be alloy electrodes exhibited moderate to high MRR; however, their RW was the highest. Although the electrolytic copper has moderate MRR performance compared to the investigated alloys, its low cost increased its performance index, making it a more suitable electrode material for EDM applications.