Mekatronik Mühendisliği Bölümü Yayın Koleksiyonu
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12416/255
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Article Citation - WoS: 9Citation - Scopus: 10Effect of Use of Cu-Cr P/M Electrodes on Machining Performance of Electric Discharge Machining(Gazi Univ, Fac Engineering Architecture, 2015) Gulcan, Orhan; Çoğun, Can; Uslan, Ibrahim; Usta, Yusuf; Cogun, Can; Çoʇun, Can; Mekatronik MühendisliğiIn this study, the effect of use of Cu-Cr powder metal (P/M) electrodes on EDM performance outputs, namely material removal rate (MRR), electrode wear rate (EWR), mean and maximum roughness of machined surface (R-a and R-z) and workpiece surface recast layer thickness, was investigated experimentally. The Cu-Cr P/M electrodes produced at different mixing ratios, compacting pressures and sintering temperatures were used to machine SAE 1040 steel. The analyses performed have shown that the electrode material is deposited on to the work surface as a layer and the powder mixing ratio, the compaction pressure and sintering temperature affect the EDM performance outputs.Article Citation - WoS: 6Citation - Scopus: 6Design and Implementation of an Electrode Feed Rate Control System in the Electrochemical Drilling Process(Springer Heidelberg, 2022) Cogun, Can; Ozerkan, Haci BekirThe interelectrode gap distance control is essential for preventing short circuit and spark discharge occurrences in the machining gap and ensuring a constant distance between the tool electrode (shortly electrode) and the workpiece throughout the electrochemical drilling (ECD) process. In this study, a gap distance control system was designed and implemented in the constructed ECD machine tool. The gap distance control strategy was based on the machining current's discrete measurement (in microsecond intervals) and changing the gap distance according to a set current value by feeding the electrode towards the workpiece or retracting it during the ECD process. The small diameter deep hole ECD experiments were conducted using 0.5 mm diameter side insulated tubular rotational electrodes with through-hole electrolyte flushing to drill Hadfield and AISI 1040 steels. The experimental results demonstrated the success of the developed control system in ECD operations yielding uniform hole geometries and smooth hole surfaces. The use of the control system eliminated the undesirable formations of spark discharges and short circuit pulses.Article Citation - WoS: 22Citation - Scopus: 26Experimental Investigation on Wire Electric Discharge Machining of Biodegradable Az91 Mg Alloy(Springer, 2021) Cogun, Can; Genc, Asim; Esen, Ziya; Bozkurt, Fatih; Urtekin, Levent; Ozerkan, Haci BekirThe AZ91 magnesium alloy, used commonly as a biodegradable material in biomedical applications, is generally formed by conventional casting method (CCM) and high-pressure die casting method (HPDCM). The AZ91 alloys exhibit poor machinability with conventional chip removal methods since they degrade at elevated temperatures. In this study, the wire electric discharge machining (WEDM) was presented as a candidate process to machine the AZ91 alloy since no cutting stresses and plastic deformations were applied by the cutting tool to the part causing elevated temperatures. In this context, the WEDM machinability of the AZ91 alloy samples produced by cold chamber HPDCM and CCM at different process parameters, was experimentally investigated. The machining performance outputs (the machining current (I), the machining rate (MR), the average surface roughness (R-a), and surface topography) were found for the varying process parameters [pulse time (t(s)), pulse-off time (t(off)), dielectric flushing pressure (P-d), and wire speed (V-w)]. The present study revealed that the I and the MR were significantly dependent on the density, the porosity, and the micro structure of the samples, and the HPDCM samples gave the higher MR and the smoother surface than that of the CCM.Article Citation - WoS: 14Citation - Scopus: 13Electrochemical Small Diameter Deep Hole Drilling of Powder Metal Steel(Univ Zagreb Fac Mechanical Engineering & Naval Architecture, 2020) Cogun, Can; Ozerkan, Haci BekirIn this study, a new hybrid electrochemical drilling (ECD) method is proposed. The method makes use of a tubular tool capable of rotating and an electrolyte flushing through the inner hole at the same time. The designed and manufactured small size ECD machine's most important features are the regulation of the tool feed rate via current feedback control and the use of a rotating tubular tool with internal electrolyte flushing. The powder metal (PM) FLN2 4405 steel was drilled by using a brass tubular tool with various combinations of machining parameters such as machining voltage, electrolyte concentration and flushing pressure, and tool rotation speed. The machining performance outputs, namely, material removal rate (MRR), average radial overcut (RADOC), conicity (CO) and hole geometries were calculated and compared in different machining conditions. The results have shown that the aforementioned variables had a direct impact on the machining performance outputs in ECD. In all experiments, MRR increased with an in increase in machining voltage, tool rotational speed, electrolyte concentration and flushing pressure. RADOC values decreased with the rotational speed of the tool. The present study shows that deep holes with precise geometries and dimensions can be drilled successfully by employing the proposed hybrid ECD method. The method is economical and environmentally friendly since it requires low machining current values (0.1 to 0.7A) and a small amount of non-hazardous halide salt solutions instead of acidic solutions throughout the drilling process.Article Citation - WoS: 7Citation - Scopus: 7Thermo-Fluid Multi-Physics Modeling and Experimental Verification of Volumetric Workpiece Material Removal by a Discharge Pulse in Electric Discharge Machining Process(Iop Publishing Ltd, 2020) Cogun, Can; Uslan, Ibrahim; Erbas, Murat; Erdem, OguzThe volume of material removed from the workpiece by a pulse (V-v) in the electric discharge machining was quantitatively determined using a multi-physics simulation model in ANSYS CFX software. Electrical heating is used in the model to simulate the plasma channel formation by defining the boundary and time-controlled current density initial conditions. Time-dependent physical properties at plasma temperature were used to reflect the actual processing environment. The heat was transferred from the plasma channel to the workpiece by electrical heating from the electrode, and V(v)was calculated by means of the amount of heat transfer. The calculated V(v)values for AISI4140, Ti6Al4V and Inconel 718 workpieces were lower than the experimental results and the difference was observed to change between 38.3% and 46.9%.Article Citation - WoS: 32Citation - Scopus: 36Effect of Powder Metallurgy Cu-B4c Electrodes on Workpiece Surface Characteristics and Machining Performance of Electric Discharge Machining(Sage Publications Ltd, 2016) Cogun, Ferah; Akturk, Nizami; Cogun, Can; Esen, Ziya; Genc, AsimThe main aim of this study is to produce new powder metallurgy (PM) Cu-B4C composite electrode (PM/(Cu-B4C)) capable of alloying the recast workpiece surface layer during electric discharge machining process with boron and other hard intermetallic phases, which eventually yield high hardness and abrasive wear resistance. The surface characteristics of the workpiece machined with a PM/(Cu-B4C) electrode consisted of 20 wt% B4C powders were compared with those of solid electrolytic copper (E/Cu) and powder metallurgy pure copper (PM/Cu) electrodes. The workpiece surface hardness, surface abrasive wear resistance, depth of the alloyed surface layer and composition of alloyed layers were used as key parameters in the comparison. The workpiece materials, which were machined with PM/(Cu-B4C) electrodes, exhibited significantly higher hardness and abrasive wear resistance than those of machined with the E/Cu and PM/Cu. The main reason was the presence of hard intermetallic phases, such as FeB, B4C (formed due to the boron in the electrode) and Fe3C in the surface layer. The improvement of the surface hardness achieved for steel workpiece when using PM/(Cu-B4C) electrodes was significantly higher than that reported in the literature. Moreover, the machining performance outputs (workpiece material removal rate, electrode wear rate and workpiece average surface roughness (Ra)) of the electrodes were also considered in this study.Article Citation - WoS: 10Citation - Scopus: 9The Effect of Powder Mixed and Heated Dielectric on Drilling Performance of Electric Discharge Machining (Edm)(Gazi Univ, Fac Engineering Architecture, 2016) Cogun, Can; Urtekin, Levent; Ozerkan, H. Bekir; Uslan, Ibrahim; Erdem, OguzIn this study, heated silicon oil with added carbon and starch powders was used as dielectric liquid, instead of common hydro-carbon based dielectrics, to obtain better hole surface quality with rotating brass tube electrode in electric discharge machining (EDM). The electro-rheometer tests were conducted to find out the suitable temperature and powder concentration values of the electro-rheological (ER) dielectric under the electric field. Higher workpiece material removal rates (MRR) was obtained in carbon powder added dielectrics than the starch powder added ones for rotating and non-rotating electrodes. The optical microscope observations of the machined hole surfaces indicated that the carbon powder added dielectrics reduced the diameter and depth of the discharge craters, thereby resulting in uniformly distributed and round top peaked surface topography. The starch powder addition to the carbon mixed dielectric further improved the surface quality for both rotating and non-rotating electrodes cases at 30 degrees C and 75 degrees C dielectric temperatures.Conference Object Citation - WoS: 21Citation - Scopus: 25Effect of Electrical Discharge Machining on Dental Y-Tzp Ceramic-Resin Bonding(Elsevier Ireland Ltd, 2017) Kucukturk, Gokhan; Gurun, Hakan; Cogun, Can; Esen, Ziya; Rona, Nergiz; Yenisey, MuratPurpose: The study determined (i) the effects of electrical discharge machining (EDM) on the shear-bond strength (SBS) of the bond between luting resin and zirconia ceramic and (ii) zirconia ceramic's flexural strength with the three-point bending (TPB) test. Methods: Sixty 4.8 mm x 4.8 mm x 3.2 mm zirconia specimens were fabricated and divided into four groups (n = 15): SBG: sandblasted + silane, TSCG: tribochemical silica coated + silane, LTG: Er:YAG laser treated + silane, EDMG: EDM + silane. The specimens were then bonded to a composite block with a dual-cure resin cement and thermal cycled (6000 times) prior to SBS testing. The SBS tests were performed in a universal testing machine. The SBS values were statistically analyzed using ANOVA and Tukey's test. To determine flexural strength, sixty zirconia specimens were prepared and assigned to the same groups (n = 15) mentioned earlier. After surface treatment TPB tests were performed in a universal testing machine (ISO 6872). The flexural strength values were statistically analyzed using ANOVA and Tukey's test (a = 0.05). Results: The bond strengths for the four test groups (mean SD; MPa) were as follows: SBG (Control), 12.73 +/- 3.41, TSCG, 14.99 +/- 3.14, LTG, 7.93 +/- 2.07, EDMG, 17.05 +/- 2.71. The bond strength of the EDMG was significantly higher than those of the SBG and LTG (p < 0.01). The average flexural strength values for the groups SBG (Control), TSCG, LTG and EDMG were 809.47, 800.47, 679.19 and 695.71 MPa, respectively (p > 0.05). Conclusions: The EDM process improved the SBS. In addition, there was no significant adverse effect of EDM on the flexural strength of zirconia. (C) 2016 Japan Prosthodontic Society. Published by Elsevier Ltd. All rights reserved.