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Specific Energy Consumption (SEC) Model for Types of Two Different Production of Fittings which is Reinforced by Chip of Copper and Brass

Year 2020, , 27 - 35, 01.03.2020
https://doi.org/10.2339/politeknik.473105

Abstract

TS 11 EN 10242 Pipe fittings (fittings) manufactured
according to standards and geometries; It is widely used in many sectors such
as aerospace, automotive and machinery production, mainly in building natural
gas and water installations. Threading of the fittings to the materials at one
time is usually carried out on CNC mill and on special manual threading
machines. In addition, fittings are also thread by universal lathes. Especially
in America and India, aluminum alloy fittings manufactured for the automotive
industry and mechanical equipment are alloyed via chips of brass and copper in
this study. Pipe fittings for the first time in the literature, considering
industrial mass production conditions, made in gradual threading via lathes and
milling by tap tool were evaluated comparatively. In this study, speed, alloy
type, and machine type are selected as parameters and the conditions which make
optimum specific energy consumption (SEC) by using  energy power conversion equations are
determined. Taguchi method was used to determine the optimum conditions.
microstructure and hardness changes in the obtained materials were
investigated. When the results of SEC were examined, it was observed that
73,91% of the processing type and 26,01 % of the rotational speed were
effective. According to these results; CNC milling as the machine type, 180 RPM
as the number of revolutions, and 8% brass reinforced 6061 aluminum alloy as
the alloy type, conditions were obtained.

References

  • [1] Weinert, K. Inasaki, I., Sutherland J. W., Wakabayashi, T., Dry Machining and Minimum Quantity Lubrication, CIRP Annals, 53, 2, 511–537, (2004).
  • [2] Düzdar, I. Kantoğlu, B. Öztürk, B., A New Product Design After Benckmarking Analysis Of Helis Gear Pumps and Optimization in Energy Consumption, Düzce Üniversitesi Bilim ve Teknoloji Dergisi, 6, 610-617, (2017).
  • [3] Ingarao, G. Lorenzo D. R. Micari, F., Sustainability issues in sheet metal forming processes. an overview, J. Clean. Prod., 19, 4, 337-347, (2011).
  • [4] Bhushan, R.K., Optimization of cutting parameters for minimizing power consumption and maximizing tool life during machining of Al alloy SiC particle composites, J. Clean. Prod., 39, 242-254, (2013).
  • [5] Balogun, V. A., Mativenga, P. T., Modelling of direct energy requirements in mechanical machining processes. J. Clean. Prod., 41, 179-186, (2013).
  • [6] Duflou, J.R., Kellens, K., Dewulf, W., Unit process impact assessment for discrete part manufacturing: a state of the art. CIRP J. Manuf. Sci. Technol., 4, 129-135, (2011).
  • [7] Hanafi, I., Khamlichi, A., Cabrera, F.M., Almansa, E., Jabbouri, A., Optimization of cutting conditions for sustainable machining of PEEK-CF30 using TiN tools. J. Clean. Prod., 33, 1-9. (2012).
  • [8] Mori, M. , Fujishima, M., Inamasu, Y., Oda, Y., CIRP Annals-Manufacturing Technology, 60, 145–148, (2011).
  • [9] Liu, N. , Zhang, Y.F., Lu, W.F., A hybrid approach to energy consumption modelling based on cutting power: a milling case, Journal of Cleaner Production, 104, 264-272, (2015).
  • [10] Negrete, C. C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production, 53, 195-203, (2013).
  • [11] Oda, Y. , Mori, M., Ogawa, K., Nishida, S., Fujishima, M., Kawamura T., a Study of optimal cutting condition for energy efficiency improvement in ball end milling with tool-workpiece inclination, CIRP Annals - Manufacturing Technology, 61, 119–122, (2012).
  • [12] Shokoohi, Y., Khosrojerdi, E., Shiadhi, R., Machining and ecological effects of a new developed cutting fluid in combination with different cooling techniques on turning operation, , Journal of Cleaner Production, 94, 330-339, (2015).
  • [13] Nas, E., Öztürk, B., Optimization of surface roughness via the Taguchi method and investigation of energy consumption when milling spheroidal graphite cast iron materials, Materials Testing For Production Technologies, 60, 5, 519-524, (2018).
  • [14] Liu, N., Wang, S.B., Zhang, Y.F., Lu, W.F., A novel approach to predicting surface roughness based on specific cutting energy consumption when slot milling Al-7075, International Journal of Mechanical Sciences, 118, 13–20, (2016).
  • [15] Öztürk, B., Küçük, Ö., Düzdar, İ., Altınbilek, Y. S., Exploring the economial reasons of the usage of unhealthy & low resisting far-east products in the water pipe systems, The Turkish Journal Of Occupational / Environmental Medicine and Safety, 2, 3, 60-72, (2017).
  • [16] Öztürk, B., Öktem, H., Said, G., Çetindağ, H. A., Erzincanlı, F., Investigation of Cooling Rate on Hardness and Microstructure in Casting Fittings Materials, Published in 4th International Symposium on Innovative Technologies in Engineering and Science, 1278-1285, (2016).
  • [17] Öktem, H., Öztürk, B., Akincioğlu, S., Investigation of energy consumption on thread machining of austempered ductile cast iron materials, 5th International Conference and Exhibition on Mechanical & Aerospace Engineering, 75, (2017).
  • [18] Weng , Y., Jia, Z., Ding, L., Pan, Y., Liu, Y., Liu, Q., Effect of Ag and Cu additions on natural aging and precipitation hardening behavior in Al-Mg-Si alloys, Journal of Alloys and Compounds, 695, 2444-2452, (2017).
  • [19] Li, J. F., Liu, P. L., Chen, Y. L., Zhang, x. H., Zheng, Z. Q., Microstructure and mechanical properties of Mg, Ag and Zn multi-microalloyed Al-(3.2-3.8) Cu-(1.0-1.4)Li alloys, Trans. Nonferrous Met. Soc. China, 25, 2103-2112, (2015)
  • [20] Choia, S. W., Chob, H. S., Kumaic, S., Titanium as an intermetallic phase stabilizer and its effect on the mechanical and thermal properties of Al-Si-Mg-Cu-Ti alloy, Materials Science & Engineering A, 678, 267–272, (2016).
  • [21] Shabestari, S.G., Moemeni, H., Effect of copper and solidification conditions on the microstructure and mechanical properties of Al–Si–Mg alloys, Journal of Materials Processing Technology, 193–199, (2004).
  • [22] Kiliçaslan, M F., Yilmaz, F., Ergen, S., Hong, S. J., Uzun, O., Microstructure and microhardness of melt-spun Al–25Si–5Fe–XCo (X = 0, 1, 3, 5) alloys, Materials Characterization, 77, 15-22, (2013).
  • [23] Entes akım trafosu ve ampermetreler teknik özellikler katalogu, (2018).
  • [24] Fanuc 1000 CNC kullanıcı rehberi, (2012).

Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli

Year 2020, , 27 - 35, 01.03.2020
https://doi.org/10.2339/politeknik.473105

Abstract

TS 11 EN 10242 Standartlara uygun
ölçülerde ve geometrilerde üretimi yapılan boru bağlantı elemanlarının
(fittings); havacılık, otomotiv ve makine üretimi gibi önemli alanlar başta
olmak üzere, bina içi doğalgaz ve su tesisatlarına kadar birçok sektörde yaygın
olarak kullanılmaktadır. Fittings malzemelere tek seferde diş açma işlemi,
genelde CNC Freze tezgâhlarında ve özel diş açma makinelerinde yapılmaktadır.
Ayrıca üniversal torna tezgâhlarında da kademeli diş açma işlemi ile de
fittings malzemeler üretilmektedir. Özellikle Amerika ve Hindistan'da otomotiv
sektörü ve makine ekipmanları için üretilen 
alüminyum alaşımlı fittings malzemeler, bu çalışmada hurda pirinç ve
bakır talaşıyla belirli oranda alaşımlandırılmıştır. Literatürde ilk defa boru
bağlantı elemanlarının, endüstride seri üretim koşulları dikkate alınarak, CNC
Freze'de kılavuzla diş açma ve tornada kademeli diş açma işlemleri ile yapılmış
ve karşılaştırmalı olarak incelenmiştir. Bu çalışmada, parametre olarak devir
sayısı, alaşım tipi ve tezgah türü seçilmiş ve enerji güç dönüşüm denklemleri
kullanılarak özel enerji tüketimi değerini (SEC (Specific Energy Consumption))
optimum yapan şartlar belirlenmiştir. Optimum şartların belirlenmesinde,
Taguchi Yöntemi kullanılmıştır. Elde edilen malzemelerin içyapıları ve sertlik
değişimleri incelenmiştir. SEC sonuçları incelendiğinde %73,91 oranda işleme
tipinin ve %26,05 oranda da devir sayısının etkili olduğu gözlemlenmiştir. Bu
sonuçlara göre tezgah türü olarak CNC freze, devir sayısı olarak 180 RPM ve
alaşım tipi olarak da %8 Prinç Takviyeli 6061 Alüminyum alaşımı seçildiğinde
optimum şartlar elde edilmiştir. 

References

  • [1] Weinert, K. Inasaki, I., Sutherland J. W., Wakabayashi, T., Dry Machining and Minimum Quantity Lubrication, CIRP Annals, 53, 2, 511–537, (2004).
  • [2] Düzdar, I. Kantoğlu, B. Öztürk, B., A New Product Design After Benckmarking Analysis Of Helis Gear Pumps and Optimization in Energy Consumption, Düzce Üniversitesi Bilim ve Teknoloji Dergisi, 6, 610-617, (2017).
  • [3] Ingarao, G. Lorenzo D. R. Micari, F., Sustainability issues in sheet metal forming processes. an overview, J. Clean. Prod., 19, 4, 337-347, (2011).
  • [4] Bhushan, R.K., Optimization of cutting parameters for minimizing power consumption and maximizing tool life during machining of Al alloy SiC particle composites, J. Clean. Prod., 39, 242-254, (2013).
  • [5] Balogun, V. A., Mativenga, P. T., Modelling of direct energy requirements in mechanical machining processes. J. Clean. Prod., 41, 179-186, (2013).
  • [6] Duflou, J.R., Kellens, K., Dewulf, W., Unit process impact assessment for discrete part manufacturing: a state of the art. CIRP J. Manuf. Sci. Technol., 4, 129-135, (2011).
  • [7] Hanafi, I., Khamlichi, A., Cabrera, F.M., Almansa, E., Jabbouri, A., Optimization of cutting conditions for sustainable machining of PEEK-CF30 using TiN tools. J. Clean. Prod., 33, 1-9. (2012).
  • [8] Mori, M. , Fujishima, M., Inamasu, Y., Oda, Y., CIRP Annals-Manufacturing Technology, 60, 145–148, (2011).
  • [9] Liu, N. , Zhang, Y.F., Lu, W.F., A hybrid approach to energy consumption modelling based on cutting power: a milling case, Journal of Cleaner Production, 104, 264-272, (2015).
  • [10] Negrete, C. C., Optimization of cutting parameters for minimizing energy consumption in turning of AISI 6061 T6 using Taguchi methodology and ANOVA, Journal of Cleaner Production, 53, 195-203, (2013).
  • [11] Oda, Y. , Mori, M., Ogawa, K., Nishida, S., Fujishima, M., Kawamura T., a Study of optimal cutting condition for energy efficiency improvement in ball end milling with tool-workpiece inclination, CIRP Annals - Manufacturing Technology, 61, 119–122, (2012).
  • [12] Shokoohi, Y., Khosrojerdi, E., Shiadhi, R., Machining and ecological effects of a new developed cutting fluid in combination with different cooling techniques on turning operation, , Journal of Cleaner Production, 94, 330-339, (2015).
  • [13] Nas, E., Öztürk, B., Optimization of surface roughness via the Taguchi method and investigation of energy consumption when milling spheroidal graphite cast iron materials, Materials Testing For Production Technologies, 60, 5, 519-524, (2018).
  • [14] Liu, N., Wang, S.B., Zhang, Y.F., Lu, W.F., A novel approach to predicting surface roughness based on specific cutting energy consumption when slot milling Al-7075, International Journal of Mechanical Sciences, 118, 13–20, (2016).
  • [15] Öztürk, B., Küçük, Ö., Düzdar, İ., Altınbilek, Y. S., Exploring the economial reasons of the usage of unhealthy & low resisting far-east products in the water pipe systems, The Turkish Journal Of Occupational / Environmental Medicine and Safety, 2, 3, 60-72, (2017).
  • [16] Öztürk, B., Öktem, H., Said, G., Çetindağ, H. A., Erzincanlı, F., Investigation of Cooling Rate on Hardness and Microstructure in Casting Fittings Materials, Published in 4th International Symposium on Innovative Technologies in Engineering and Science, 1278-1285, (2016).
  • [17] Öktem, H., Öztürk, B., Akincioğlu, S., Investigation of energy consumption on thread machining of austempered ductile cast iron materials, 5th International Conference and Exhibition on Mechanical & Aerospace Engineering, 75, (2017).
  • [18] Weng , Y., Jia, Z., Ding, L., Pan, Y., Liu, Y., Liu, Q., Effect of Ag and Cu additions on natural aging and precipitation hardening behavior in Al-Mg-Si alloys, Journal of Alloys and Compounds, 695, 2444-2452, (2017).
  • [19] Li, J. F., Liu, P. L., Chen, Y. L., Zhang, x. H., Zheng, Z. Q., Microstructure and mechanical properties of Mg, Ag and Zn multi-microalloyed Al-(3.2-3.8) Cu-(1.0-1.4)Li alloys, Trans. Nonferrous Met. Soc. China, 25, 2103-2112, (2015)
  • [20] Choia, S. W., Chob, H. S., Kumaic, S., Titanium as an intermetallic phase stabilizer and its effect on the mechanical and thermal properties of Al-Si-Mg-Cu-Ti alloy, Materials Science & Engineering A, 678, 267–272, (2016).
  • [21] Shabestari, S.G., Moemeni, H., Effect of copper and solidification conditions on the microstructure and mechanical properties of Al–Si–Mg alloys, Journal of Materials Processing Technology, 193–199, (2004).
  • [22] Kiliçaslan, M F., Yilmaz, F., Ergen, S., Hong, S. J., Uzun, O., Microstructure and microhardness of melt-spun Al–25Si–5Fe–XCo (X = 0, 1, 3, 5) alloys, Materials Characterization, 77, 15-22, (2013).
  • [23] Entes akım trafosu ve ampermetreler teknik özellikler katalogu, (2018).
  • [24] Fanuc 1000 CNC kullanıcı rehberi, (2012).
There are 24 citations in total.

Details

Primary Language Turkish
Subjects Engineering
Journal Section Research Article
Authors

Burak Öztürk 0000-0002-1018-6545

Özkan Küçük 0000-0002-4337-4454

Publication Date March 1, 2020
Submission Date October 22, 2018
Published in Issue Year 2020

Cite

APA Öztürk, B., & Küçük, Ö. (2020). Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli. Politeknik Dergisi, 23(1), 27-35. https://doi.org/10.2339/politeknik.473105
AMA Öztürk B, Küçük Ö. Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli. Politeknik Dergisi. March 2020;23(1):27-35. doi:10.2339/politeknik.473105
Chicago Öztürk, Burak, and Özkan Küçük. “Bakır Ve Pirinç Talaşı Ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli”. Politeknik Dergisi 23, no. 1 (March 2020): 27-35. https://doi.org/10.2339/politeknik.473105.
EndNote Öztürk B, Küçük Ö (March 1, 2020) Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli. Politeknik Dergisi 23 1 27–35.
IEEE B. Öztürk and Ö. Küçük, “Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli”, Politeknik Dergisi, vol. 23, no. 1, pp. 27–35, 2020, doi: 10.2339/politeknik.473105.
ISNAD Öztürk, Burak - Küçük, Özkan. “Bakır Ve Pirinç Talaşı Ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli”. Politeknik Dergisi 23/1 (March 2020), 27-35. https://doi.org/10.2339/politeknik.473105.
JAMA Öztürk B, Küçük Ö. Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli. Politeknik Dergisi. 2020;23:27–35.
MLA Öztürk, Burak and Özkan Küçük. “Bakır Ve Pirinç Talaşı Ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli”. Politeknik Dergisi, vol. 23, no. 1, 2020, pp. 27-35, doi:10.2339/politeknik.473105.
Vancouver Öztürk B, Küçük Ö. Bakır ve Pirinç Talaşı ile Takviye Edilmiş Boru Bağlantı Elemanlarının İki Farklı Üretim Türü İçin (SEC) Özel Enerji Tüketim Modeli. Politeknik Dergisi. 2020;23(1):27-35.
 
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