Publication: Flowforming makinesinin şanzıman parametrelerinin tasarımı ve optimizasyonu
Abstract
Flowforming teknolojisi, stratejik bir öneme sahip ileri bir soğuk plastik şekillendirme yöntemidir. Bu yöntem, silindirik ve konik yapıdaki döner simetrik parçaların çok hassas bir şekilde üretilmesine imkan tanımaktadır. İşlemin temel prensibi, şekillendirme makaralarının radyal kuvvetleri ile malzemenin cidar kalınlığını azaltarak parçaların boyuna uzamasını sağlamaktır. Flowforming sayesinde çeşitli boyutlarda borular hassas bir şekilde üretilirken, malzeme mukavemeti de artmaktadır. Makaraların malzeme ile temas ettiği noktada uygulanan kuvvet, malzemenin akma sınırını aşarak plastik deformasyona yol açar. Bu deformasyon dikkatlice kontrol edilerek, et kalınlığında ±0,05 mm hassasiyetle üretim yapılabilir. Bu yöntem, özgül mukavemeti artırarak daha sağlam ve dayanıklı parçaların üretilmesini sağlar. Bu yöntem, savunma sanayii, havacılık ve uzay gibi kritik alanlarda yaygın olarak kullanılmaktadır. Flowforming, talaşlı imalata kıyasla çok daha hassas üretim toleransları ve malzeme mukavemetinde artış sunar. Çok yönlülüğü ve sürdürülebilirlik potansiyeliyle modern endüstriyel uygulamalarda kritik bir rol üstlenmektedir. CNC teknolojisi ve elektronik cetveller gibi yeniliklerle donatılarak, hassasiyetin ön planda olduğu uygulamalarda çok daha etkili hale gelmiştir. Flowforming makinelerinin ana mekanik bileşeni olan headstock spindle grubu, üretim enerjisinin büyük bir kısmından sorumludur. İşlem sırasında, motor veya aktarma organı grubundaki parametrelerin optimize edilmesi, motor verimliliğini ve performansı arttırmaktadır. Fakat mevcut sistemlerde, iş parçasının büyüklüğüne ve malzeme sertliğine bağlı olarak motorun ürettiği tork ve devir değerlerinde dalgalanmalar meydana gelmekte, bu durum ise düzensiz tork dağılımına sebep olmakta ve üretim verimliliğini düşürmektedir. Bu sorunu aşmak için, motordan alınan hareketi istenilen tork değerinde iletebilen yeni bir şanzıman sistemi tasarlanmıştır. Tasarlanan şanzıman sistemi, motorun sabit rotasyonel hızlarda dengeli tork aktarımı yapmasını sağlayarak daha büyük çaplı parçaların işlenmesine olanak tanıyacak, enerji verimliliğini arttıracak ve maliyetleri azaltacaktır. Tasarlanan şanzıman sistemi, bilgisayar destekli tasarım (CAD) kullanılarak modellenmiştir. Yapılan nümerik hesaplamalar ile şanzıman dişlilerinin reaksiyonu, mil boyutlandırması, yataklama elemanlarının seçimi, yağlama ve gövde yorulma durumları detaylı bir şekilde incelenmiştir. Sistem gereksinimlerini karşılamak üzere, malzeme dayanımı ve tasarım optimizasyonu üzerine odaklanılmıştır. Flowforming makinelerinde kullanılmak üzere tasarlanan şanzıman sistemi, endüstriyel uygulamalarda çok yönlü faydalar sağlayacaktır. Sistem, daha büyük çaplı ve mukavemeti yüksek parçaların üretimine imkan tanırken, üretim maliyetlerini de düşürecektir. Bu çalışma, Endüstri 4.0'ın sürdürülebilirlik ve verimlilik hedefleri doğrultusunda konvansiyonel üretim yöntemlerinin modernize edilmesi açısından önemli bir katkı sunmaktadır.
Flowforming technology is an advanced cold plastic forming method of strategic importance. This technique enables the high-precision production of cylindrical and conical rotationally symmetric components. The fundamental principle of the process is to reduce the wall thickness of the material by applying radial forces with forming rollers, thereby increasing the length of the workpiece. Flowforming allows for the precise production of tubes in various sizes while also enhancing material strength. The force applied at the contact point between the rollers and the material exceeds the material’s yield strength, leading to plastic deformation. This deformation is carefully controlled, allowing for production with a wall thickness accuracy of ±0.05 mm. This method enhances specific strength, enabling the production of stronger and more durable components. This technology is widely used in critical fields such as defense, aerospace, and space industries. Compared to conventional machining methods, flowforming offers higher production accuracy and improved material strength. Its versatility and sustainability potential make it a key player in modern industrial applications. With advancements such as CNC technology and electronic measuring systems, flowforming has become even more effective in precision-demanding applications. The headstock spindle group, a key mechanical component of flowforming machines, is responsible for a significant portion of the production energy. During the process, optimizing the motor and drivetrain parameters enhances motor efficiency and performance. However, in existing systems, torque and speed fluctuations occur during the machining of large-diameter workpieces, reducing manufacturing efficiency. To address this issue, a new transmission system has been designed, capable of transferring motor motion at the desired torque level. The newly developed transmission system ensures stable torque transfer at constant rotational speeds, allowing the processing of larger-diameter workpieces, increasing energy efficiency, and reducing production costs. The transmission system was modeled using computer-aided design (CAD). Through numerical calculations, the reaction of gears, shaft sizing, bearing selection, lubrication system, and fatigue analysis of the housing were examined in detail. The focus was placed on material strength and design optimization to meet system requirements. The designed transmission system for flowforming machines will offer multiple industrial benefits. It will enable the production of larger-diameter and high-strength components while simultaneously reducing production costs. This study provides a significant contribution to the modernization of conventional manufacturing methods in line with Industry 4.0's sustainability and efficiency goal.
Flowforming technology is an advanced cold plastic forming method of strategic importance. This technique enables the high-precision production of cylindrical and conical rotationally symmetric components. The fundamental principle of the process is to reduce the wall thickness of the material by applying radial forces with forming rollers, thereby increasing the length of the workpiece. Flowforming allows for the precise production of tubes in various sizes while also enhancing material strength. The force applied at the contact point between the rollers and the material exceeds the material’s yield strength, leading to plastic deformation. This deformation is carefully controlled, allowing for production with a wall thickness accuracy of ±0.05 mm. This method enhances specific strength, enabling the production of stronger and more durable components. This technology is widely used in critical fields such as defense, aerospace, and space industries. Compared to conventional machining methods, flowforming offers higher production accuracy and improved material strength. Its versatility and sustainability potential make it a key player in modern industrial applications. With advancements such as CNC technology and electronic measuring systems, flowforming has become even more effective in precision-demanding applications. The headstock spindle group, a key mechanical component of flowforming machines, is responsible for a significant portion of the production energy. During the process, optimizing the motor and drivetrain parameters enhances motor efficiency and performance. However, in existing systems, torque and speed fluctuations occur during the machining of large-diameter workpieces, reducing manufacturing efficiency. To address this issue, a new transmission system has been designed, capable of transferring motor motion at the desired torque level. The newly developed transmission system ensures stable torque transfer at constant rotational speeds, allowing the processing of larger-diameter workpieces, increasing energy efficiency, and reducing production costs. The transmission system was modeled using computer-aided design (CAD). Through numerical calculations, the reaction of gears, shaft sizing, bearing selection, lubrication system, and fatigue analysis of the housing were examined in detail. The focus was placed on material strength and design optimization to meet system requirements. The designed transmission system for flowforming machines will offer multiple industrial benefits. It will enable the production of larger-diameter and high-strength components while simultaneously reducing production costs. This study provides a significant contribution to the modernization of conventional manufacturing methods in line with Industry 4.0's sustainability and efficiency goal.