Akademik Veri Yönetim Sistemi
Özkaya E. (Yürütücü), Aslantas K., Çiçek A.
TÜBİTAK Projesi, 2232 - Yurda Dönüş Araştırma Burs Programı, 2022 - 2026
Machining takes a central position in industrial production and is an important part in the value chain. The globally growing requirements and the technological change trigger high competitive pressure and costs. They force manufacturing companies to increase their productivity and to minimize the resources. Added to this is the digital transformation through Industry 4.0 and Smart Factory, which are fundamentally changing classical mechanical engineering. Furthermore, the requirements for machining high-performance materials such as nickel-based and titanium alloys or composite materials are increasing. Due to their excellent properties, they are used in turbine and nuclear power technology, automotive industry, aerospace technology, defense industry and others. They can be characterized by lower cutting speeds, shorter tool life, longer machining times and higher manufacturing costs. The high ductility of these materials favors undesirable vibrations, so that regenerative chatter occurs more frequently and leads to the formation of ribbon chip and snarled chip, especially in processes with continuous cutting. The consequences are often premature tool failure, poor surface quality – including tool breakage and machine breackdown. In order to positively influence the above-mentioned aspects in the machining process, material properties are improved, tool geometries are modified, cutting parameters and tool coatings are adapted and various Metalworking Fluids (MWF) are developed. It is difficult, expensive and time-consuning to experimentally determine efficiency of MWFs in cutting zone, so that this important influence is often not taken into account. The expertise of Dr. Ekrem Özkaya ties with these requirements and problems and generates new innovations. The overall objective of this research plan is modeling, simulation and minimization of negative influences in machining technology. The objective focuses on minimization of the manufacturing inaccuracies resulting from the process by simulation-based methods and techniques. Suitable applications for this are, Computational Fluid Dynamics (CFD), Finite-Element Method (FEM) and Fluid-Structure Interaction (FSI). Since together with the development of mathematical models, algorithms, scripts and Application Programming Interfaces (APIs), it is possible to describe the fluid mechanical and rheological behavior and to calculate interactions of structural mechanical deformations, forces and internal stresses. In addition, various technologies such as Additive Manufacturing (AM) and Artificial Intelligence (AI) will be used to avoid disruptive process influences. The combination results in specific requirements both on the part of the simulation methods and on the part of the technologies, so that the development of software modules is often required, which are further objectives in this research plan. The range and complexity of the research plan require interdisciplinary work in developing suitable modeling and simulation techniques and software modules. The generation of simulation methods, the implementation of associated flow processes of fluids (Newtonian and non-Newtonian), the multitude of numerical and algorithmic techniques, the non-isothermal effects, viscosity, discretization and additional transport of solid particles (e.g. chips), microcavities, anisotropic, turbulent mixing zones etc. as well as the increase of efficiency of the simulations and the optimal design of the manufacturing processes, represent only a part of the expertise required to find solutions in this research plan. With the use of different technologies, not only close collaboration with industry but also a multidisciplinary collaboration of different scientific disciplines is promoted.