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Article Citation - WoS: 113Citation - Scopus: 147Experiments and Finite Element Simulations on Micro-Milling of Ti-6al Alloy With Uncoated and Cbn Coated Micro-Tools(Elsevier, 2011) Oezel, T.; Thepsonthi, T.; Ulutan, D.; Kaftanoglu, B.This paper presents experimental investigations and finite element simulations on micro-milling of Ti-6Al-4V alloy with fine grain uncoated and cBN coated micro-end mills. Micro-milling of Ti-6Al-4V using uncoated and cBN coated tungsten carbide micro-end mills are conducted; surface roughness, burr formation and tool wear are measured. Effects of machining parameters on surface roughness, burr formation, and tool wear for uncoated and cBN coated micro-tools are investigated. Finite element modelling is utilized to predict forces, temperatures, and wear rate for uncoated and cBN coated micro-tools. Predicted temperature and tool wear contours for uncoated and cBN coated micro-tool edges reveal advantages of cBN coatings. Optimization studies on the experimental results are also conducted to identify the optimum process parameters which minimize both surface roughness and burr formation concurrently. (C) 2011 CIRP.Article Citation - WoS: 17Citation - Scopus: 18A New Approximation in Determination of Vertical Displacement Behavior of a Concrete-Faced Rockfill Dam(Springer, 2011) Gurbuz, Ayhan; Gürbüz, Ayhan; Gürbüz, Ayhan; Department of Civil Engineering; Department of Civil EngineeringA new simplified method based on one-dimensional displacement theory and 2-D finite element (FE) analysis was developed to predict the vertical displacement behavior of a concrete-faced rockfill dam. The FE analyses were carried out at the end of construction (EOC) and the end of first filling of reservoir. The proposed method was calibrated by using continuously monitored vertical displacement of the dam's body to determine the mobilized modulus of elasticity of the rockfills at the EOC. The prediction capability of the method was demonstrated using field measurements against the findings from the 2-D FE analysis simulating characteristics of construction stages of the dam. The validity of the method was also examined on another membrane-faced rockfill dam by comparing the geodetic measurements of vertical displacement measurements of the dam's body with the calculated vertical displacements from 2-D FE analysis at the EOC.Article Citation - WoS: 12Citation - Scopus: 11Effect of Constitutive Material Model on the Finite Element Simulation of Shear Localization Onset(Elsevier, 2020) Yilmaz, Okan Deniz; Oliaei, Samad Nadimi BavilOne of the most challenging problems in the field of machining is to determine the onset of shear localization. The consequences of the emergence of shear localized chips are fluctuations in the machining forces, tool wear, deterioration of the surface quality and out-of-tolerance machined components. Several constitutive material models are developed for the simulation of shear localization during machining, especially for Ti6Al4V. However, the accuracy and capability of the proposed models for the prediction of shear localization onset have not been investigated yet. In this study, the effect of different constitutive material models in the prediction of shear localization onset has been investigated. Different material models are studied including the Johnson-Cook (J-C) material model with Cockcroft-Latham damage model, J-C material model with a J-C damage model, models based on modified J-C material models (MJ-C) with strain softening terms, and material model with power-law type strain hardening and strain rate sensitivity, with polynomial thermal softening and polynomial temperature-dependent damage. The results of the finite element models are verified using orthogonal cutting experiments in terms of chip morphology and machining forces. Metallography techniques are used along with SEM observations to elucidate the distinction between continuous and shear localized chips. The results of this study indicate that three models are capable of predicting shear localization onset. However, when compared to the experiments, where a critical cutting speed of 2.8 m/min is obtained for shear localization onset, the results revealed that the model proposed by Sima and Ozel (2016) which is a model based on MJ-C model with temperature-dependent overarching modifier and temperature-dependent material model parameters is more accurate for the prediction of shear localization onset during machining Ti6Al4V. This model is shown to reveal a good prediction for the machining forces as well.Conference Object Citation - Scopus: 3Fem-Based Design Modifications and Efficiency Improvements of a Brushed Permanent Magnet Dc Motor(Institute of Electrical and Electronics Engineers Inc., 2017) Tarvirdilu-Asl,R.; Zeinali,R.; Ertan,H.B.This paper describes design modifications of a brushed permanent magnet DC motor. Test motor is modeled using a Finite Element Method (FEM) based software. Model accuracy is investigated by comparing measurement and simulation results. Reducing material consumption in motor fabrication while the motor develops the desired torque at a higher efficiency is aimed in this paper. Modifications are done in three stages and simulations results are also presented. These results are also compared to simulation results of the test machine. © 2017 IEEE.Conference Object Citation - WoS: 176Citation - Scopus: 220Investigations on the Effects of Multi-Layered Coated Inserts in Machining Ti-6al Alloy With Experiments and Finite Element Simulations(Elsevier Science Bv, 2010) Ozel, T.; Sima, M.; Srivastava, A. K.; Kaftanoglu, B.This paper presents investigations on turning Ti-6Al-4V alloy with multi-layer coated inserts. Turning of Ti-6Al-4V using uncoated, TiAlN coated, and TiAlN + cBN coated single and multi-layer coated tungsten carbide inserts is conducted, forces and tool wear are measured. 3D finite element modelling is utilized to predict chip formation, forces, temperatures and tool wear on these inserts. Modified material models with strain softening effect are developed to simulate chip formation with finite element analysis and investigate temperature fields for coated inserts. Predicted forces and tool wear contours are compared with experiments. The temperature distributions and tool wear contours demonstrate some advantages of coated insert designs. (C) 2010 CIRP.Conference Object Prediction of plastic instability and forming limits in sheet metal forming(2011) Şanay,B.; Kaftanoglu,B.In this study, FLD's are predicted by simulating Nakazima test using a finite element software. Strain propagation instability criterion is used to evaluate the limit strains from the finite element simulations. SAE 1006, material is used in this study and 7 different specimen geometries are analyzed. Furthermore, FLD's are also predicted by theoretical approaches namely; Keeler's model, maximum load instability criterion, Swift-Hill model and Storen-Rice model. At the end of the study, the calculated FLD's are compared with the experimental results. © 2011 IBF (RWTH Aachen) & IUL (TU Dortmund).
