MEHMET ALPER SOFUOĞLU, Selim GÜRGEN, Fatih H. ÇAKIR, Sezan ORAK, Melih C. KUŞHAN

Yeni Sıcak Ultrasonik Yardımlı İmalat Ünitesi Tasarımı ve Ekonomik Analizi

Ultrasonik yardımlı işleme, takıma veya iş parçasına belirli bir titreşim uygulanarak iş parçasının işlenmesi süreci olup son işlem uygulamalarında yüzey özelliklerinin iyileşmesi, kesme kuvvetlerinin azalması ve takım ömrünü arttırılması amacıyla uygulanır. Sıcak işleme ise talaş kaldırması zor olan malzemelerin termal yumuşamasını sağlayarak kesme işleminin kolaylaştırılmasını amaçlayan bir işlemdir. Bu işlem sayesinde kesme kuvvetlerinde azalma ve takım ömründe artış görülmektedir. İşlenebilirliği zor malzemeler için son yıllarda ortaya çıkan en önemli melez yöntemlerden biri ise sıcak titreşim yardımlı talaşlı işlemedir. Bu işlem ultrasonik yardımlı işleme ile sıcak işlemeyi birleştiren yeni bir melez imalat yöntemidir. Bu çalışma kapsamında ülkemizde yaygın olmayan bu üretim tekniği için yeni bir imalat ünitesi tasarımı yapılmıştır. Bu yeni üretim yöntemi ile özellikle savunma ve havacılık sektöründe işlenebilirliği düşük olan süperalaşım, paslanmaz çelik gibi malzemeler hem yüzey kalitesi arttıralarak imal edilebilecek hem de takım maliyeti gibi masraflar azaltılacaktır. Yöntemin hayata geçmesiyle de savunma ve havacılık gibi kritik bir alanlarda ileri teknoloji edinilerek milli bir birikim sağlanmış olacaktır. Tasarlanan imalat ünitesi üniversal torna tezgahlarına ilave bir modül olarak eklenebilmekte ve ileride CNC tezgahlar için de yaygınlaştırılabilme potansiyeline sahiptir.

Anahtar Kelimeler:

Ultrasonik yardımlı işleme, sıcak işleme, melez yöntemler, ultrasonik sistem tasarımı

Design and Economic Analysis of a Novel Hot Ultrasonic Machining System

Ultrasonic assisted machining uses vibrational cutting generally for finishing operations to improve surface properties of the workpiece, reduce cutting force and enhance tool life. On the other side, hot machining takes advantage of thermal softening of difficult-to-cut materials during operations. This process reduces cutting forces and increases tool life. As a hybrid manufacturing method, hot ultrasonic machining is a high-rank important process emerging in the last years. This method brings vibrational cutting and hot machining together to be benefited from both techniques. Within the scope of this study, a new manufacturing system was designed for this production technique which is not common in Turkey. With this new production method, materials such as superalloys and stainless steels, which are particularly hard to machine materials in the defense and aerospace sectors, can be manufactured both by increasing the surface quality and by reducing costs such as tooling costs. With the realization of the method, advanced technology will be gained in critical areas such as defense and aviation. The designed manufacturing system is able to integrated into universal turning lathes and has a potential to be adapted to CNC machines in the near future.

Keywords:

Ultrasonic assisted machining, hot machining, hybrid methods, ultrasonic system design,

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