Abdil Kus

Implementation of 3D Optical Scanning Technology for Automotive Applications

Reverse engineering (RE) is a powerful tool for generating a CAD model from the 3D scan data of a physical part that lacks documentation or has changed from the original CAD design of the part. The process of digitizing a part and creating a CAD model from 3D scan data is less time consuming and provides greater accuracy than manually measuring the part and designing the part from scratch in CAD. 3D optical scanning technology is one of the measurement methods which have evolved over the last few years and it is used in a wide range of areas from industrial applications to art and cultural heritage. It is also used extensively in the automotive industry for applications such as part inspections, scanning of tools without CAD definition, scanning the casting for definition of the stock (i.e. the amount of material to be removed from the surface of the castings) model for CAM programs and reverse engineering. In this study two scanning experiments of automotive applications are illustrated. The first one examines the processes from scanning to re-manufacturing the damaged sheet metal cutting die, using a 3D scanning technique and the second study compares the scanned point clouds data to 3D CAD data for inspection purposes. Furthermore, the deviations of the part holes are determined by using different lenses and scanning parameters.

Thermocouple and Infrared Sensor-Based Measurement of Temperature Distribution in Metal Cutting

In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining.

A comparative study of 3D scanning in engineering, product and transport design and fashion design education

The aim of this paper is to evaluate the use of three‐dimensional (3D) scanning technologies for design and engineering courses. This paper will provide a comparative discussion of the current 3D scanning technologies; and then describes three experimental studies in engineering, transport design and fashion design. Using 3D scanner technology the experiments tested the transferral of a variety of different data from scanned organic 3D shapes to 3D CAD packages for learning and teaching in undergraduate education.

Investigation of the WEDM of Al/B4C/Gr reinforced hybrid composites using the Taguchi method and response surface methodology

Abstract In this study, the effects of machining parameters on the material removal rate (MRR) and surface roughness (Ra) were investigated during the cutting of Al/B4C/Gr hybrid composites by wire electrical discharge machining (WEDM). Wire speed (WS), pulse-on time (Ton) and pulse-off time (Toff) were chosen as the control factors. The L27 (33) orthogonal array in the Taguchi method was used in the experimental design and for the determination of optimum control factors. Response surface methodology was also used to determine interactions among the control factors. Variance analysis (ANOVA) was applied in the determination of the effects of control factors on the MRR and Ra. According to the ANOVA results, the most effective parameters on MRR and Ra were wire speed with a 85.94% contribution ratio, and pulse-on-time with a 47.7% contribution ratio. The optimum levels of the control factors for MRR and Ra were determined as A3B3C3 and A1B1C2. In addition, second-order predictive models were developed for MRR and Ra; correlation coefficients (R2) were calculated as 0.992 and 0.63.

Evaluation of surface roughness and material removal rate in the wire electrical discharge machining of Al/B4C composites via the Taguchi method

This study researched the effects of machining parameters on surface roughness and material removal rate in the wire electrical discharge cutting of high-density Al/B4C metal matrix composites produced via the hot pressing method. Wire tension, reinforcement percentage, wire speed, pulse-on time and pulse-off time were set as the control factors. The Taguchi L18 (21 × 34) orthogonal array was used in the experiment design and determination of the optimum control factors. Variance analysis was applied to determine the effects of the control factors on the surface roughness and material removal rate. The results showed the most effective parameters to be pulse-on time (30.22%) for surface roughness and wire speed (83.20%) for material removal rate, and the optimum levels of the control factors to be A2B1C2D1E1 and A2B2C3D2E2, respectively. Predictive equations were then developed by applying linear regression analysis, and the adjusted correlation coefficients were calculated as 0.61 for surface roughness and 0.785 for material removal rate.

Experimental study on the flexural properties of 3D integrated woven spacer composites at room and subzero temperatures

The flexural behavior of the 3D integrated woven spacer composites with carbon fiber-reinforced polymer face sheets are performed with epoxy and polyester matrix in the warp direction. The static loading of foam core carbon/epoxy and carbon/polyester composite sandwich panels in three-point flexural test was characterized at room temperature (23℃) and at liquid nitrogen temperature (−40℃). Macro-fracture morphology and progress have been examined to understand the deformation and failure mechanism. Significant increases in the flexural strength with brittle type core shear failure were observed at low temperatures as compared with the corresponding room temperature behavior. The performance of the epoxy-based composite is compared to the polyester one. Significant changes in the flexural properties of the composites have been found, first related to the temperature and then to the resin type. The flexural properties of the epoxy-based composites were affected greatly by temperature and exhibited higher flexural performance than polyester-based composites at low temperatures.

A Modular Training Project for Vocational Education and Improvement in Turkey

Various vocational training methods, most of which overlap with lifelong learning programmes, are being used to address the problem of unemployment – an issue of vital importance, especially for developing countries. This article examines the introduction of a modular certification project in Turkey supported by EU training funds. The objective of the project is to enable people who are unemployed to find work and people in employment to improve their professional skills and competences, and therefore their opportunities. The researchers observed the employment status and development of the 245 people who received a certificate. They found that 89% either had found work in a sector consistent with their training, thanks to their participation in the project, or had to taken up a different position in their current field of employment.

Experimental Investigation of Sheet Metal Forming Using a Recyclable Low Melting Point Alloy Tool

Abstract Due to intense competition in automotive industry, new car models have to be launched as quickly as possible. A re-evaluation of the design and development phases has reshaped product development in order to get product earlier than competitors. Prototype production is one of the longest stages of product development due to physical verification activities. Shortening of this process will provide more opportunity to get project schedule earlier. Rapid prototype technologies are usually used as a guide for visual and packaging analysis. However, there is a requirement to use these parts for functional testing as well. Developing alternative rapid tooling methods which shorten the physical prototype production phase, while adequately supporting visual, packaging and functional aspects of sheet metal forming, can lead to considerable savings in vehicle prototype development. In this study, sheet metal prototype part using recyclable low melting point alloy was experimentally investigated by analysing dimensional conformance of tools and parts. In addition to wear performance, thickness reduction was investigated for stamped parts.

Impact behavior of multi-layer carbon skin composite sandwich panels with 3D spacer fabric

Abstract For this study, the strengths against impact effects of multi-layer composite sandwich panels reinforced by additional lamination structures using 3D spacer fabric have been investigated. To determine the impact strengths of the produced sandwich panels, falling weight tests with a constant impact energy of 15 J were performed on all of the samples, and the loads and absorbed energy were monitored as a function of time. In addition, the damage mechanisms occurring in the structure during impact were examined. Overall, according to the analysis of the damaged surface, the different impacts created a regional penetration area. Furthermore, no deviation in the breakdown of the surface texture was observed in the regions outside of the penetration area.

Application of carbon reinforced composites and rapid prototyping in low volume automotive production

Abstract In this publication, a method was developed for the production of plastic parts for the use in low volume automotive production. The hollow parts having a complex geometry were produced in blown plastic injection molds. The part production method employed a combination of carbon fiber reinforced composites and rapid prototyping technology. Surface operations were applied on the core model and the effects of the surface quality were researched as a case study. The fused deposition modeling method was used to build the core from soluble material. This technique affected the inside surface roughness and quality of the final parts. As these types of components require smooth surfaces for good air flow and low resistance, the surface area of the physical model of the soluble core was unfortunately too rough to be used directly in the carbon fabric application process and consequently, required preliminary surface treatment in order to improve the surface quality of the manifold part. Specimens were fabricated using different surface treatments in order to determine the smoothest surface quality. The best result was obtained using the acetone-gelcoat post-processing method.