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Öğe Calculation and Estimation of Surface Roughness and Energy Consumption in Milling of 6061 Alloy(Hindawi Ltd, 2020) Ozturk, Burak; Kara, FuatThe best surface quality that can be achieved in manufactured products has become the main goal of industrial enterprises in recent years. Due to the subsequent increase in energy consumption costs from rising energy efficiency rates, manufacturers are contributing to this issue by applying advanced design functions for their machines. In line with the same objective, this study investigated the machinability of 6061 aluminum alloy, which has a high throughput rate and low machinability featuring built up edge. The aim of the research was to optimize the cutting parameters for minimum surface roughness (Ra) and energy consumption (EC) using a CNC milling machine. At the same time, measurements of power indices (A) of both the spindle and the X-axis motors were carried out with the goal of improved chip removal as compared to literature studies. The experiment was designed according to the Taguchi L-16 (2(1) x 4(3)) orthogonal index. Four different cutting speeds (60, 120, 180, and 240 m/min), feed rates (0.10, 0.15, 0.20, and 0.25 mm/rev), and cutting depths (0.5, 0.10, 0.15, and 0.20 mm) and two different cooling methods (coolant fluid and dry cutting) were selected as cutting parameters.Öğe Development of femoral component design geometry by using DMROVAS (design method requiring optimum volume and safety)(Emerald Group Publishing Ltd, 2020) Ozturk, Burak; Erzincanli, FehmiPurpose This study aims to design a femoral component with minimum volume and maximum safety coefficient. Total knee prosthesis is a well-established therapy in arthroplasty applications. And in particular, with respect to damaged or weakened cartilage, new prostheses are being manufactured from bio-materials which are compatible with the human body to replace these damages. A new universal method (design method requiring optimum volume and safety [DMROVAS]) was propounded to find the optimum design parameters of tibial component. Design/methodology/approach The design montage was analyzed via the finite element method (FEM). To ensure the stability of the prosthesis, the maximum stress angle and magnitude of the force on the knee were taken into consideration. In the analysis process, results revealed two different maximum stress areas which were supported by case reports in the literature. Variations of maximum stress, safety factor and weight were revealed by FEM analysis, and ANOVA was used to determine the F force percentage for each of the design parameters. Findings Optimal design parameter levels were chosen for the individual's minimum weight. Stress maps were constructed to optimize design choices that enabled further enhancement of the design models. The safety factor variation (SFV) of 5.73 was obtained for the volume of 39,219 mL for a region which had maximum stress. At the same time, for a maximum SFV and at the same time an average weight, values of 37,308 mL and 5.8 for volume and SFV were attained, respectively, using statistical methods. Originality/value This proposed optimal design development method is new and one that can be used for many biomechanical products and universal industrial designs.Öğe Energy consumption, mechanical and metallographic properties of cryogenically treated tool steels(De Gruyter Poland Sp Z O O, 2023) Savas, Ahmet Fevzi; Oktem, Hasan; Ozturk, Burak; Uygur, Ilyas; Kucuk, OzkanThis article examines energy consumption, microstructure, mechanical properties, and the change in the wear amount during the machining of GGG-42 cast iron material with two types of guide cutting tool produced by powder metallurgy and casting method The tap. tool samples used as cutting tool material were first subjected to the traditional hardening process and then to two different cryogenic treatments (24-16 h) at -90?. The internal structures of the guide samples obtained from conventional heat treatment and cryogenic treatment were examined with an optical microscope and Scanning Electron Microscope. The hardness changes were checked with Vickers measurement method. The wear amount forming after the threading process was measured with CLEMEX program in a light microscope. In addition, by measuring the current amount drawn during the machining of the cast iron with guide cutter tools, instantaneous power consumption during cutting and power consumption during chip removal were calculated. The application of heat treatment and cryogenic process increased the hardness of the guides. Moreover, the power consumption during the chip removal was also seen to increase. This can be commented that cutting tools produced with powder metallurgy perform better than the cutting tools produced via casting and 30% energy saving.Öğe Finite Element-Based Simulation of Cooling Rate on the Material Properties of an Automobile Silent Block(Hindawi Ltd, 2020) Ozturk, Burak; Kara, FuatThe aluminum silent block is the part that connects the front suspension mounting and the road wheels. These products are used in high-speed cars and are subject to high engineering stresses. Over time, fractures occur in the connection part of these products due to insufficient strength. These problems are related to production metallurgy, which led to the concept of this study. During mass production, these parts are manufactured using the aluminum extrusion method. In this study, a rapid cooling process using water was applied, with the aim of improving the mechanical properties of the connecting part exposed to high dynamic loads. Samples were taken from the regions of these products which differed in thickness and width, and microhardness and tensile tests were performed for each region. The effects of both the extrusion cooling rate and the regional flash cooling on the material properties were then characterized. As a result of the isothermal transformation, the grain size in the microstructure of the material had shrunk. According to the findings, in this type of production, an average increase in strength of 25% was observed in the parts of the material subjected to maximum stress. The stress and safety coefficient values were found using finite element analysis, and curves were then drawn showing the differences in the safety coefficient values from the different points. As a result of cooperation between university and industry, the material and mechanical properties of an automobile part were improved in this study. This research has shown that, in terms of the accuracy of the results, it is very important to consider the variations in different regions of the product when defining the mechanical properties of any material produced by applying casting, heat treatment, and plastic forming methods.Öğe Multi-Objective Optimization of Machinability and Energy Consumption of Cast Iron Depending on Cooling Rate(Mdpi, 2025) Ozturk, Burak; Kara, FuatCooling rates in cast iron significantly impact its microstructure, leading to bainitic transformation instead of ferritic structures, resulting in microstructures with higher pearlite content and even cementite formation. Consequently, this transformation causes hardness values to vary between 160 and 320 HB, directly affecting the material's machinability. Energy efficiency has become a critical focus in sustainable production techniques and cost-effective machining processes. This variation directly influences machinability, with higher hardness generally improving surface quality. Energy efficiency in machining is crucial for sustainable production, and Specific Cutting Energy Consumption (SCEC) has become a key metric in evaluating machinability. Using genetic algorithms (GA) and Response Surface Methodology (RSM), this study optimized machining parameters for energy consumption and surface finish. GA results indicated that a cutting speed of 200 m/min and a feed rate of 0.15 mm/rev minimized surface roughness to 1.359 Ra while reducing Specific Energy Consumption (SEC) from 3.25 to 2.83 Wh/mL. The lowest surface roughness (1.0 mu m) was observed at a hardness of 320 HB, with the same cutting parameters. RSM analysis identified optimal parameters as a cutting speed of 150-200 m/min, a feed rate of 0.2 mm/rev, and a hardness of 220-245 HB, balancing energy efficiency and surface quality. ANOVA showed that cutting speed and feed rate contributed to 30% of the surface roughness variability and 45% of the energy consumption variability.Öğe A new specific carbon footprint (SCF) theory of serial aluminum alloys in hard turning(Emerald Group Publishing Ltd, 2025) Ozturk, Burak; Kara, FuatPurposeThis research aims to address the critical challenge of optimizing machining processes for serial aluminum alloys, focusing on reducing carbon emissions and energy consumption while maintaining high surface quality. The study introduces the specific carbon footprint (SCF) model to evaluate CO2 emissions per unit material removed, aiming to enhance sustainable production practices in mass manufacturing.Design/methodology/approachUsing response surface methodology (RSM), experiments were conducted on 5,000, 6,000 and 7,000 series aluminum alloys to assess the impact of cutting speed and feed rate on surface quality, energy consumption and carbon footprint. Energy usage data were collected, and analysis of variance was used to identify the contributions of process parameters.FindingsThe results revealed that feed rate is the most influential factor, contributing 51.8% to the SCF, followed by cutting speed at 32%. Optimal conditions reduced CO2 emissions by 37%, cutting the carbon footprint from 516.4 tons to 325 tons annually. Among the materials tested, the 6,000 series exhibited the best machinability, balancing low energy consumption and high surface quality.Research limitations/implicationsThe proposed SCF model serves as a novel metric for sustainable manufacturing, enabling precise evaluation of carbon emissions in machining processes. This work establishes a benchmark for optimizing machining parameters, significantly reducing environmental impact in mass production scenarios.Originality/valueThis study pioneers the integration of SCF into machining optimization and offers actionable insights for sustainable manufacturing. It highlights the potential of using RSM to simultaneously optimize energy efficiency, surface quality and carbon emissions, providing a valuable framework for future research and industrial applications.Öğe Reduction of Stress Variations on Sections (ROSVOS) for a Femoral Component(Springer, 2021) Ugur, Levent; Ozturk, Burak; Erzincanli, FehmiTotal knee prostheses have become established arthroplasty applications in the treatment of damaged or weakened cartilage. New implants are being produced using bio-materials which are compatible with human tissue. In the industry, these prostheses are modeled and manufactured in different design geometries. This study investigated using a novel method for an ideal geometry designed to prevent fracture problems caused by design errors and metallurgical weakness in femoral component geometry. This approach is presented in a flowchart demonstrating its implementation, orientation, and evaluation via finite element analysis. Unlike those in the literature, stress variations in the design surface cross sections were evaluated in this proposed design method, for different design types and angles. In this study, the design surface was divided into eight horizontal and ten vertical sections. The main objective of this study is to minimize the stress variations in these sections and to obtain the lowest possible volume value. As a result, stress exceeding the critical ratio was observed in four sections. In addition, three design parameters were found to be the most important for achieving maximum safety and minimum volume in this femoral component design. The method presented in this study aims to evaluate the ideal geometry of models and selection can be applied for the production of many industrial and biomechanical products.
