Browsing by Author "Tekkaya, AE"
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Article Citation Count: 0Assessment and improvement of elementary force computations for cold forward rod extrusion(Springer Heidelberg, 2005) Tekkaya, Ahmet Eeman; Egemen, N; Tekkaya, AE; Manufacturing EngineeringTwo commonly used analytical force computation methods for cold forward rod extrusion are evaluated by means of precise finite element computations. The upperbound model by Avitzur based on the spherical velocity field and the model by Siebel based on a quasi-upper-bound solution are considered. It has been found that the pure deformation forces obtained by summing the ideal force and shear force terms deviate between +25% and -20% from the finite element solutions. Larger deviations, however, occur for the Coulomb-friction term in the container. A new model based on an elasto-static analysis combined with numerical analysis is suggested to compute this term. This new model supplies also the accurate pressure distribution within the container.Article Citation Count: 11Comparison of various preforms for hot forging of bearing rings(Elsevier Science Sa, 2005) Tekkaya, Ahmet Eeman; Tekkaya, AE; Özhan, F; Manufacturing EngineeringProduction of bearing rings by hot forging is investigated in this study. The aim of the study is to determine a feasible preform at the first station of the forming process such that the tool wear is prolonged and tool fracture is prevented. For this purpose, it is assumed that the contact pressure at the interface between tools and workpiece is the predominant process parameter. The contact pressures are determined by precise thermo-mechanical coupled finite element analyses based on elastic-plastic material description. Material flow curves for various temperatures and strain-rates are determined in velocity controlled upsetting tests. Cooling experiments are used to determine the heat transfer coefficients. Accuracy of the numerical models has been verified by extensive numerical convergence studies and finally by comparing with experimental measurements. The analysed preforms are evaluated using a scheme of weight-factors for the various tool parts. Finally, a preform is suggested for which the weighted total tool pressure could be reduced by 15%. (c) 2005 Elsevier B.V. All rights reserved.Article Citation Count: 115The development of ring rolling technology(verlag Stahleisen Mbh, 2005) Tekkaya, Ahmet Eeman; Tekkaya, AE; Stanistreet, TF; Manufacturing EngineeringA thorough survey of work on ring rolling published in the English and German languages by 2004 is presented. The process is briefly introduced and a set of ideals are stated, as the target for all developments in the area. The main challenges which inhibit attainment of these ideals are given, and the process is compared with alternatives. The main body of the review is organised in four parts: the evolution of the design of ring rolling equipment is described, including detailed discussion of the design and manufacture of preforms; the methods used to investigate the process are reviewed, separated into experimental and theoretical categories; the insights gained from these investigations are organised according to the challenges identified at the outset; developments in the control and operation of the process are described. Having given a set of ideal targets for the process, the state of current knowledge about ring rolling is assessed in order to predict likely developments: process modelling capability is nearly able to predict rolling behaviour for a complete cycle with sufficient accuracy to allow effective use of models for design of rolling schedules and preforms; analysis of material behaviour is relatively mature for steel rings, but has scope for significant extension for titanium and aluminium alloys and composites; design choices that seek to extend the flexibility of the process have had some exploration, but could be extended. Finally, the seminal contribution of Professor Kopp is briefly described.Review Citation Count: 57The development of ring rolling technology - Part 2: Investigation of process behaviour and production equipment(Wiley-blackwell, 2005) Tekkaya, Ahmet Eeman; Tekkaya, AE; Stanistreet, TF; Manufacturing EngineeringThis is the continuation of a thorough survey of work on ring rolling published in the English and German languages up to 2004 [see No. 2/3, p. 111-120]: The methods used to investigate the process are reviewed, separated into experimental and theoretical categories; the insights gained from these investigations are organised according to the challenges identified at the outset; developments in the control and operation of the process are described. Having given a set of ideal targets for the process, the state of current knowledge about ring rolling is assessed in order to predict likely developments: process modelling capability is nearly able to predict rolling behaviour for a complete cycle with sufficient accuracy to allow effective use of models for design of rolling schedules and preforms; analysis of material behaviour is relatively mature for steel rings, but has scope for significant extension for titanium and aluminium alloys and composites; design choices that seek to extend the flexibility of the process have had some exploration, but could be extended.Article Citation Count: 27A guide for validation of FE-simulations in bulk metal forming(Springer Heidelberg, 2005) Tekkaya, Ahmet Eeman; Manufacturing EngineeringNumerical analysis of metal forming processes is an everyday practice in industry. Forming loads, material flow, forming defects such as underfills, laps, and even cracks, stresses in dies and punches, as well as product properties like new hardness distribution, dimensional accuracies, and residual stresses are predicted by numerical analysis and used for technology generation. Most of the numerical analysis is done by the finite element method made available for engineers and technicians by numerous powerful commercial software packages. These software packages act as black-boxes and usually hide the complicated numerical procedures and even their crucial parameters from the applier. Therefore, the question arises during industrial applications: how accurate is the simulation, and how can the results be assessed? The aim of this paper is to provide a guideline to assess the results of metal forming simulations. Although some ideas are valid for any metal forming process, bulk forming is the primary concern. The paper will address firstly the possible sources of error in a finite element analysis of bulk forming processes. Then, some useful elementary knowledge will be summarized. Various levels of validation such as result and ability validation and assessment will be discussed. Finally, interpretation of results will be treated. In this content also some suggestions will be given.Article Citation Count: 50Residual stress state and hardness depth in electric discharge machining: De-ionized water as dielectric liquid(Taylor & Francis inc, 2005) Tekkaya, Ahmet Eeman; Elkoca, O; Erden, Abdulkadir; Erden, A; Manufacturing Engineering; Department of Mechatronics EngineeringProcedures and results of experimental work to measure residual stresses and hardness depth in electric discharge machined surfaces are presented. Layer removal method is used to express the residual stress profile as a function of depth caused by a die sinking type EDM. Thin stressed layers are removed from machined samples by electrochemical machining. Corresponding deformations due to stress relaxation are recorded for each removal to determine the stress profile from elasticity theory. The relational dependence of the machining parameters with residual stresses is obtained and a semi-empirical model is proposed for plastic mold steel for de-ionized water as dielectric liquid. These stresses are found to be increasing rapidly with respect to depth, attaining to its maximum value, around the yield strength, and then fall rapidly to compressive residual stresses in the core of the material since the stresses within plastically deformed layers are equilibrated with elastic stresses.