Bülent Ekici

A Numerical and an Experimental Investigation of a High-Pressure Die-Casting Aluminum Alloy

In this paper, a computer simulation of a high-pressure die casting of aluminum alloy was performed using a commercially available software and also compared with the real castings of the same alloy. The commercial aluminum alloy was Etial 150 (AlSi12Cu) that is used for flange which is a washing machine part. Mold filling, solidification, temperature distribution, porosity, and velocity of the liquid metal during high-pressure die casting were investigated using the model through numerical simulation. The simulation results proved that the model values used in simulations were accurate in order to apply for experimental casting. After this numerical model, the flange part was cast experimentally according to the obtained optimum parameters from simulation results. Then, specimens from the experimental casting were tested for tensile, hardness, and microstructure analyses. Accordingly, the test results are rather sound which demonstrates that simulation provides profitable die casting. Consequently, it was observed from this study that simulation is not only useful for enhancing casting quality but also very economical and practical, which helps to reduce time spent on experiments. Moreover, simulation can reveal porosity and helps to minimize this defect. Thus, computer simulation should be used for casting applications more often, and simulation programs should be developed further.

Optimization of high hardness perforated steel armor plates using finite element and response surface methods

ABSTRACT In this article, finite element simulations and response surface method are used to optimize perforated plate parameters for ballistic protection. After statistically validating the relationship between residual velocity and geometric parameters, a response optimizer was used to find the best combination of design parameters to stop a threat with less areal density. Finally, the optimized solution was checked both numerically and experimentally to show the effectiveness of the developed methodology. The weight is decreased by 28% when compared with monolithic steel armor having the same antiballistic performance.

Finite element analysis on the optimal material choice and cavity design parameters for MOD inlays exposed to different force vectors and magnitudes

Abstract This simulation study evaluated the effect of three different inlay materials (composite, glass ceramic, zirconia), cavity design parameters (isthmus width and depth) and different force vectors and magnitudes on the stress distribution within mesio-occlusal-distal (MOD) inlays and the remaining enamel and dentin. The mechanical performance of inlays was evaluated using 3-D finite element analysis (FEA) method. Three different restoration materials and hard tissues of the restored tooth with different cavity depth (2–5 mm) and width (2–4 mm) were exposed to occlusal loading with different magnitudes from 10 to 130 kg at varying angles between 0° and 15°. The maximum von Mises stresses were calculated for the inlays, tooth structure and bonded surfaces. Response Surface Optimization method was implemented into the finite element software package in order to design cavity shapes with more favourable interfacial stresses for bonded restorations under occlusal loading. Teeth restored with resin composite exhibited the highest von Mises Stress, followed by glass ceramic and zirconia. The increase in isthmus width decreased interfacial shear stresses in zirconia MOD inlay but the increase in cavity depth did not change the stress levels for all three materials. According to mechanical safety factor, inlay and tooth structure remained within the mechanical limits in three parameters (material, magnitude of force, cavity shape) but negatively affected by the force vector.

Effect of surface geometry on low-velocity impact behavior of laminated aramid-reinforced polyester composite

The aim of this study is to investigate the effect of surface geometry for low-velocity impact applications. To achieve this purpose, aramid fiber-reinforced laminated polyester composite with various geometries such as cylindrical, elliptical, and spherical were prepared, and low-velocity impact properties were investigated numerically and experimentally. All properties such as orientation, fiber volume fraction, matrix material, and average thickness are the same in all samples. Experimental low-velocity impact behaviors of structure were determined by drop weight tester at low velocity 2.012 m/s. Simulations were carried out by LS-Prepost 4.2 and LS-Dyna v971 software. By this way, results of impact tests were verified and modeled with finite element method. Results of the impact tests showed that the elliptical samples have the highest energy absorption capability due to effective stress transfer capacity. According to experimental results, maximum energy absorption rate difference is 17% between elliptical 10 mm and cylindrical 5 mm geometries.