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Yayın Tribo-corrosion behavior of electroplating, nitrocarburizing, and QPQ processes on barrel finishing(Walter de Gruyter GmbH, 2023-11-27) Yücel, Aysu Hande; Yılmaz, Alpay; Bakkal, Mustafa; Kuzu, Ali TanerIn this study, the effects of nitrocarburizing, QPQ, and Cr coating on the surface properties of 32CrMoV12-10 gun barrels are discussed. Hardness measurements, pin-on-disc tests, and anodic polarization tests were performed to examine the hardness values, wear resistance, friction coefficient, and corrosion resistance. The hardness of the specimen treated with QPQ was found to be the highest. Comparing the hardness profiles, it was observed that the casing depth of the nitrocarburized sample was shallower than that of the QPQ-treated sample. The pin-on-disc test revealed that the nitrocarburized sample exhibited a high coefficient of friction, while the Cr-coated sample showed the lowest coefficient of friction. Analyzing the Tafel polarization curve, it was determined that the nitrocarburized and QPQ-treated specimens demonstrated similar levels of corrosion resistance. However, it can be noted that the QPQ-treated specimen had a slightly lower corrosion rate.Yayın Analysis of mechanical behavior of termoplastic composites(Necip Fazıl YILMAZ, 2022-03-04) Kuzu, Ali Taner; Kosemen, Elifnur; Yücel, Aysu Hande; Bakkal, MustafaThis paper presents the effect of fiber orientation on the tensile, compression, impact, and flexuralproperties of glass fiber reinforced acrylic-based thermoplastic composites. The mechanical behaviorof three different composite plates, produced by the resin transfer molding (RTM) method, with0°/90°/45°, 0°/90° and ±45° glass fiber orientations were investigated by carrying out tensile,compression, three-point bending and Charpy impact tests. A Weibull distribution model wasimplemented to explain the variation in mechanical properties of the acrylic-based composite.According to Weibull analysis results with 63.2% probability, the highest tensile strength (561 MPa),compressive strength (293 MPa) and impact values (19.44 J) were obtained when the plate with0°/90° glass fiber orientation was tested, whereas the highest flexural strength was obtained when theplate with 0°/90°/45° was tested.Yayın The development of a hybrid cutting model for workpiece temperature distribution via advection heat partition approach(Springer Science and Business Media Deutschland GmbH, 2023-04-15) Kara, Mehmet Emre; Kuzu, Ali Taner; Bakkal, MustafaThis paper presents a novel hybrid cutting model for the prediction of workpiece temperature distribution during the dry milling process of compacted graphite iron (CGI). The hybrid model consists of an analytical force model based on a mechanistic approach and finite element analysis (FEA) based on the thermal model. The heat generated during the milling process transferred to the workpiece is computed via the advection heat partition model. The workpiece temperature distribution obtained through the heat loads, using as boundary conditions in the FEA, was calculated by means of cutting forces. The developed force and thermal models have been experimentally validated, and good agreement between the measured and calculated results has been observed. The energy and active work calculations show that by doubling the feed during CGI milling, an energy saving of about 10% is achieved despite almost doubling the cutting forces.Yayın Investigation of residual stresses induced by milling of compacted graphite iron by x-ray diffraction technique(Springer, 2024-04) Kara, Mehmet Emre; Kuzu, Ali Taner; Bakkal, MustafaThis study investigates the relationship between residual stresses, cutting parameters, and machining performance in the milling process of compacted graphite iron (CGI). X-ray diffraction (XRD) analysis is employed to measure residual stresses on the cast and milled surfaces, while cutting force modeling is utilized to calculate the tangential force, power, and active work. The results demonstrate that tensile residual stresses are predominant on the milled surfaces, attributed to the both mechanical and thermal loads generated during milling. By analyzing various cutting conditions, it is observed that lower feeds contribute to reduced plastic deformation, resulting in lower residual stress levels. Additionally, higher cutting speeds lead to higher temperatures, but due to the shorter machining time, heat accumulation is limited, resulting in higher residual stresses, especially at low feeds. At high feeds, residual stresses decreased as the cutting speed increased. The interplay between cutting parameters and residual stresses highlights the need for optimizing cutting conditions to enhance fatigue strength in CGI components. These findings provide valuable insights for process optimization and quality control in the milling of CGI materials.Yayın Enhancing mechanical performance of FDM-printed ABS parts through annealing optimization(John Wiley and Sons Inc, 2025-06-18) Kösemen, Elifnur; Bakkal, Mustafa; Kuzu, Ali TanerThis study examines the impact of annealing on the mechanical properties of acrylonitrile butadiene styrene (ABS) parts produced using fused deposition modeling (FDM). The research investigates how different annealing temperatures (90°C, 105°C, and 120°C), production orientations (upright, on edge, and flat), and infill patterns influence hardness, tensile strength, and impact resistance. Experiments were conducted using a Stratasys F370 printer, and samples were tested following ISO standards for mechanical performance. Results indicated that annealing at 90°C and 105°C generally improved hardness, tensile strength, and impact resistance, particularly for upright and on-edge orientations. However, annealing at 120°C led to a decrease in these properties, likely due to microstructural changes observed through scanning electron microscopy (SEM) and differential scanning calorimetry (DSC) analysis. The study highlights the importance of optimizing production parameters and annealing conditions to achieve desired mechanical properties in FDM-printed ABS parts. These findings may inform post-processing strategies for enhancing the reliability and performance of additive manufactured components, particularly for applications in industries utilizing ABS materials for customized and prototype parts.Yayın Investigation of residual stresses induced by turning of hot forged and heat treated AA7075(Springer Science and Business Media Deutschland GmbH, 2024-12) Tok, Görkem; Kuzu, Ali Taner; Bakkal, MustafaThis study investigates the impact of cutting parameters on residual stress in components made from AA7075 material, which were hot forged and subsequently subjected to T6 heat treatment. Using the Taguchi experimental design, two distinct cutting cases—face turning and circumferential turning—were devised to assess residual stress at different sections of the part. During the turning process, force measurements were conducted with a dynamometer, and residual stress was subsequently measured using the X-ray diffraction method. The results indicate that both mechanical and thermal loadings significantly influence residual stress. Notably, spindle speed has the most substantial effect on residual stress in both face turning and circumferential turning, with an observed increase of up to 30% and 20%, respectively, in tensile residual stress for Case 1 and Case 2. When thermal loads are predominant, residual stress tends to be tensile, with measurements reaching as high as 89 MPa.Yayın Predictive modelling of surface roughness and residual stress induced by milling of hot forged and heat treated AA7075(Springer Nature, 2025-11-03) Tok, Görkem; Dinçer, Ammar Tarık; Kuzu, Ali Taner; Bakkal, MustafaThis study investigates the influence of cutting parameters on residual stress and surface roughness during the milling of hot-forged and T6 heat-treated AA7075 components. Using Taguchi L9 and full-factorial experimental designs and regression modelling, the research highlights important relationships between cutting parameters (cutting speed, feed rate, and depth of cut), residual stress and surface roughness. Higher cutting speeds (350 m/min) and lower feed rates (0.1 mm/tooth) significantly minimized residual stresses, with hoop stress values decreasing from 108.7 MPa at lower speeds (150 m/min) to approximately 73.4 MPa at higher speeds, and axial stress values ranging from 45.9 MPa to 88.5 MPa. Surface roughness (Ra) was most influenced by feed rate, with measurement values varying between 0.25 mu m and 0.92 mu m. Support Vector Regression (SVR) demonstrated better accuracy for predicting residual stress (MAPE: 11.5%) and surface roughness (MAPE: 7%), outperforming Lasso and Ridge regression models. These findings provide a consistent framework for optimizing cutting parameters and enhancing residual stress and surface roughness in AA7075 machining processes, offering practical implications for improving component performance and manufacturing efficiency.Yayın Investigation and prediction of surface integrity induced by milling of hot forged and heat treated AA7075(Motto, 2024-11-03) Tok, Görkem; Dinçer, Ammar Tarık; Kuzu, Ali Taner; Bakkal, Mustafa; Saklakoğlu, İ. EtemThis study examines the influence of cutting parameters on surface integrity, focusing on residual stress and surface roughness, in hot-forged and T6 heat-treated AA7075 components post-milling. Using the Taguchi L9 DOE method, orthogonal cutting milling experiments were performed, with residual stress measured via nondestructive X-ray diffraction (XRD). The analysis indicated that lower cutting speeds reduce residual stress, with down milling causing compressive and up milling causing tensile stresses. A proposed model showed a significant correlation between cutting force and residual stress—higher cutting forces increased residual stress. Surface roughness assessment revealed that feed rate greatly impacts residual stress, with lower feed rates reducing roughness. These insights will aid in developing a regression model for predicting outcomes in future experiments, enhancing the understanding and control of surface integrity in milling AA7075 components.Yayın Dairesel testere makine parametrelerinin yüzey kalitesine etkisi incelenmesi(Motto, 2024-11-03) Çakır, Hasan; Yılmaz, Mahmut; Yeter, Alper; Karagüzel, Umut; Kuzu, Ali Taner; Bakkal, Mustafa; Saklakoğlu, İ. EtemDairesel testere ile yapılan kesimlerde gelişen teknolojiyle birlikte kesilen yüzeylerde yüksek yüzey kalitesi beklentisi artmıştır. Yüzey kalitesine kesme işleme sırasında kullanılan dairesel testere ve testere malzeme yapısı doğrudan etki etmektedir. Aynı zamanda makine çalışma parametreleri de yüzey kalitesine etki etmektedir. Yapılan bu çalışmada makine çalışma parametreleri içersinde yer alan ilerleme ve kesme hızlarında, farklı değerler kullanılarak kesme deneyleri yapılmıştır. Deneyler veri toplama cihazı ile makine gövdesi üzerine yerleştirilen ivmeölçer sensörlerden titreşim verileri toplanmıştır. Toplanan veriler, veri toplama cihazı arayüz programında işlenerek maksimum ivme değerleri ve ivmelerin ortalama karekök değerleri hesaplanmıştır. Hesaplanan veriler ile krest faktörünün farklı ilerleme ve kesim hızlarında değeri bulunmuştur. Yüzey pürüzlülük ölçüm cihazı kullanılarak kesim yapılan parçaların yüzey pürüzlülük değeri tespit edilmiştir. Deneyler sonucunda makinede meydana gelen titreşimlerin yüzey pürüzlülüğüne olan etkisi araştırılmıştır.Yayın Investigation of process parameters in rotary swaging(TICMET, 2023-11-16) Bakkal, Mustafa; Karagüzel, Umut; Kuzu, Ali Taner; Kurt, Hasan Aytuğ; Çakır, HasanRotary swaging is a metalworking process used to reduce the diameter of a cylindrical workpiece or to shape it into a desired form. It is a cold-forming process, meaning it is carried out at room temperature or slightly elevated temperatures without the need for additional heat. Rotary swaging is particularly useful for creating components with a taper or complex geometries. In this study, focusing on an effects of die angle and feeding rate upon specified tubular geometry which have 2 mm thickness. An identified load was applied to the tubular geometry in Simufact finite element software for 3 different die angles and feed rates. As a result, optimum die angle and feed rate were determined.
