Research Article
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Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability

Year 2022, Volume: 6 Issue: 2, 276 - 285, 30.12.2022
https://doi.org/10.46460/ijiea.1136221

Abstract

Punches and dies employed in sheet metal “V” bending have been obtained generally from stock materials, AISI 4140 and EN C45 (Ck 45), in industrial applications through machining. The fact that local and different manufacturing methods have been applied in manufacturing these punches and dies has gained great significance in terms of external dependency and economy. The purpose of this study is to manufacture punches and dies used in “V” bending process from manganese steel via cast method and compare the newly obtained molds with presently used molds in terms of machinability and surface roughness. In this study, the experimental samples from both AISI 4140 and manganese steel were machined at different cutting parameters (cutting speed, feed rate, cutting depth), hence they were compared by analyzing with regard to chip morphology, cutting tool edge wear and surface roughness. At the end of the study, it was concluded that the punches and dies manufactured from manganese steel produced in foundry and widely found are alternatives compared to available AISI 4140 steel molds in terms of machinability.

Supporting Institution

Bu araştırma Batman Üniversitesi Bilimsel Araştırma Projeleri (BAP) Birimi

Project Number

Btübap-2018-Tek-1

Thanks

We would like to thank Batman University Scientific Research Projects Unit (Project no: BTUBAP-2018-TEK-1) for their financial support. We commemorate Associate Professor Zülküf DEMİR, who contributed and contributed to all scientific studies and passed away in 2019 due to COVID.

References

  • Basmaci, G., & Sayin, L. (2019). Experimental Investigation of the Springback Amount of Copper Sheet Plates Forming By “V” Bending Method. Uluslararası Teknolojik Bilimler Dergisi, 11(3), 147-154.
  • Ozek, C. & Akkelek, H. (2021). Investigation of Deep Drawability of Rectangular Shaped Cups in Deep Drawing Dies. International Journal of Innovative Engineering Applications, 5(2), 187-194. DOI: 10.46460/ijiea.1006144
  • Kam, M. (2016). Experimental analyses of the Dynamic Behaviors of Cryogenically processed Shafts, PhD Thesis, Düzce University, Institute of Sciences, Mechanical Engineering, Düzce, Turkey.
  • Uzkut, M., & Özdemir, İ. (2001). Investigation of the effect of changing heating speeds applied to different steels on mechanical properties. Dokuz Eylül University Engineering Faculty Journal of Science and Engineering, 3(3), 65-74.
  • Avner, S.H., (1986). Introduction to Physical Metallurgy, McGraw Hill Book Company, 2.ed., New York, 315-336
  • Oliveira, F., Hernandez, L., Berrios, J.A., Villalobos, C., Pertuz, A. and Cabrera, E.S.P., 2000, Corrosion-fatigue properties of a 4340 steel coated with Commonoy 88 alloy, applied by HVOF thermal spray, Surface and Coatings Technology, 140(2), 128-135.
  • Charre, M. D., (2004). Microstructure of steel and cast irons, (Trans. J.H. Davidson), Springer-Verlag Berlin Heidelberg New York, p.417.
  • Buytoz, S., (2004). Investigation of mechanical behaviors of AISI 4340 steel after surface modification processes with nitruration and GTA welding method, PhD Thesis, Fırat Univ. Institute of Sciences, Elazığ, p.190.
  • Kesti, E., (2009). Investigation of the effects of C-4140 steel on the temperament of environment of microstructure and mechanical properties, PhD Thesis, Seljuk University Institute of Sciences, Konya.
  • Tüfenk E., (2012). Investigation of Austenitic Manganese Steels with Different Chemical Compositions after Heat treatment, Master Degree Thesis, Ondokuz Mayıs University Institute of Sciences, Samsun
  • Subramanyam, D.K., (2005). Austenitic Manganese Steels. ASM Handbook, Properties and Selection: Irons, Steels, and High Performance Alloys, ASM Int., the United States of America, Vol. 01, 1274-1302.
  • Nejat S., (1995). High manganese austenitic steels and their sources. Journal of Metal and Source, 66, 36-41.
  • Duflou, J., R., Vancza, J., Aerens, R. (2005). Computer Aided Process Planning for Sheet Metal Bending: A State of the Art, Computers in Industry, 56, 747–771.
  • De Vin, L. J. (1994). Computer aided process planning for the bending of sheet metal components, Doctoral Dissertation, Enschede the Netherlands, ISBN 90-9007217-9.
  • De Vin, L. J., Streppel, A.H., Kalsi, H. J. J., Singh, U.P. (1995). Sensitivity analysis for air bending, Proceedings of the 3rd International Conference on Sheet Metal, ISBN: 0-9527664-0 X, 221–230.
  • De Vin, L. J., Streppel, A.H., Lutters, D. Kals, H.J.J. (1994). A process model for air bending in CAPP applications, Proceedings of the 2nd International Conference on Sheet Metal, ISBN: 1-85923-025-3, 17–28.
  • Lutters, D., Streppel, A.H., Kals, H.J.J. (1997). Adaptive press brake control in air bending, Proceedings of the 5th International Conference on Sheet Metal, ISBN: 1- 85923-072-5, 471–480.
  • Ötü, R., Demirci, H. İ. (2013)., Farklı Bükme Yöntemleri Uygulanarak V Bükme Kalıplarında AA 5754-O Sac Malzeme ile Elde Edilen Numunelerin Geri Esneme Miktarının Tespiti, Makine Teknolojileri Elektronik Dergisi, 10 (3), 27-42.
  • Tekiner, Z., (2004). An experimental study on the examination of springback of sheet metals with several thicknesses and properties in bending dies, Journal of Materials Processing Technology, 145, 109–117.
  • Özdemir, M., Gökmeşe, H., Dilipak, H., Yılmaz, V. (2104). Farklı ısıl işlemlerin 16Mo3 (1.5415) sac malzemenin ileri-geri esneme miktarına etkisinin deneysel ve mikroyapısal olarak incelenmesi, Akademik Platform ISITES 2014 Sempozyumu Karabük, (pp.148-155).
  • Tekaslan, Ö., Şeker, U. 2009. “Pirinç sac malzemelerin geri esneme miktarlarının tespiti”, 5. Uluslararası İleri Teknolojiler Sempozyumu (IATS’09).
  • Durgun, I., Yigit, K., Aydin, H., & Bayram, A. (2017). “Investigation of Mechanical Properties of Bismuth and Stann Mold Alloys Employed in Metal Sheet Forming Molds”, Uludağ University Engineering Faculty Journal, 22(3), Number 3, 11-20, DOI: 10.17482/uumfd.364084.
  • Adıyaman, O., (2019). Investigation of Manufacturability of Sheet-Metal Punches Produced by Manganese Steel, International Engineering and Science Symposium, 20-22 June, Siirt/Turkey, (pp.794-811).
  • Adıyaman, O. Kilic ,M. Yakut, R. (2021). Investigation of time-production performance of punch and dies produced from manganese steel material by casting method, International Symposium of Scientific Research and Innovative Studies, 22-25 February, Bandirma/Turkey, (pp. 215-226).
  • Adıyaman, O. Kilic, M. Yakut, R. (2021). Manganli çelikten döküm yöntemi ile üretilen bükme kaliplarinin aşinma daranişlarinin incelenmesi, International Symposium On Engineering, Natural And Social Sciences, ISENS-21, 25-28 November 2021 Batman/Turkey, (pp.110-117).
  • CKB Makine Kalip. Retrieved June 24, 2022, from http://www.ckbmakina.com.tr/?products
  • Sandvik Coromant. Retrieved June 24, 2022, from www.sandvik.coromant.com/tr, solutions for automotive components
  • Korloy. Retrieved June 24, 2022, from www.korloy.com/tr/download/cata.do
  • ISO Online Browsing Platform (OBP). Retrieved June 24, 2022, from www.iso.org/obp/ui/#iso:std:iso:8688:-1:ed-1:v1:en.do
  • Ulutan, M., Çelik, O., Gasan, H., Er, Ü. (2010). Effect of Different Surface Treatment Methods on the Friction and Wear Behavior of AISI 4140 Steel, Journal of Materials Science & Technology,, 26(3), 251-257.
  • Elbah, M., Yallese, M., Aouici, H., Mabrouiki, T. (2013). Comparative assessment of wiper and conventional ceramic tools on surface roughness in hard turning AISI 4140 steel, Measurement, 46, 3041–3056.
  • Khrais, S.K., Lin Y.J. (2007). Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel, Wear, 262, 64–69.
  • Aslan, E., Camuşçu, N., Birgören, B. (2007). Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al2O3 + TiCN mixed ceramic tool, Materials and Design, 28, 1618–1622.
  • Özler, L., Tosun, N., İnan, A. (2000). Investigation of Surface Roughness in Hot Machining of Austenitic Manganese Steel, Turk J Engin Environ Sci, 24, 287-296.
  • Kıyak, M., Uysal, A., Çakır, O., Altan, E. (2012). Tool life in orthogonal turning of high manganese steel with rounded hard metal tools, 3 National Machining Symposium, (pp. 496-502).
  • Demir, B. (2004). Examination of double-phase steel producibility from Ç4140 steel”, Technology, 4(1), 121-127.

Döküm Yöntemi ile Manganlı Çelik Malzemeden Üretilen Abkant Pres Zımba ve Dişi Kalıpların İşlenebilirlik Yönünden İncelenmesi

Year 2022, Volume: 6 Issue: 2, 276 - 285, 30.12.2022
https://doi.org/10.46460/ijiea.1136221

Abstract

Sac metal bükmede kullanılan zımba ve dişi kalıplar endüstriyel uygulamalarda genellikle AISI 4140 ve EN C45 (Ck 45) kütük malzemelerden talaşlı imalat yöntemiyle elde edilmektedir. Bu kalıpların imalatında yerel ve farklı imalat yöntemlerinin uygulanması dışa bağımlılık ve ekonomiklik anlamında önem kazanmaktadır. Bu çalışmada amaç, döküm yöntemiyle manganlı çelikten “V” bükmede kullanılan zımba ve dişi kalıplarının imal edilerek elde edilen yeni kalıpların mevcut kalıplarla işlenebilirlik ve yüzey pürüzlülüğü yönüyle karşılaştırılmasıdır. Çalışmada hem AISI 4140 hem de manganlı çelikten deney numuneleri farklı kesme parametrelerinde (kesme hızı, ilerleme, talaş derinliği) işlenerek, talaş morfolojisi, kesici takım uç aşınması ve yüzey pürüzlülüğü yönünden analiz edilerek mukayese edilmiştir. Çalışma sonunda yerelde bulunan dökümhanelerde üretilebilen ve yaygın olarak bulunabilen manganlı çelikten üretilen zımba ve dişi kalıpların mevcut AISI4140 çelikten talaşlı imalat yöntemiyle üretilen kalıplara göre işlenebilirlik yönünden de alternatif olduğu sonucuna varılmıştır.

Project Number

Btübap-2018-Tek-1

References

  • Basmaci, G., & Sayin, L. (2019). Experimental Investigation of the Springback Amount of Copper Sheet Plates Forming By “V” Bending Method. Uluslararası Teknolojik Bilimler Dergisi, 11(3), 147-154.
  • Ozek, C. & Akkelek, H. (2021). Investigation of Deep Drawability of Rectangular Shaped Cups in Deep Drawing Dies. International Journal of Innovative Engineering Applications, 5(2), 187-194. DOI: 10.46460/ijiea.1006144
  • Kam, M. (2016). Experimental analyses of the Dynamic Behaviors of Cryogenically processed Shafts, PhD Thesis, Düzce University, Institute of Sciences, Mechanical Engineering, Düzce, Turkey.
  • Uzkut, M., & Özdemir, İ. (2001). Investigation of the effect of changing heating speeds applied to different steels on mechanical properties. Dokuz Eylül University Engineering Faculty Journal of Science and Engineering, 3(3), 65-74.
  • Avner, S.H., (1986). Introduction to Physical Metallurgy, McGraw Hill Book Company, 2.ed., New York, 315-336
  • Oliveira, F., Hernandez, L., Berrios, J.A., Villalobos, C., Pertuz, A. and Cabrera, E.S.P., 2000, Corrosion-fatigue properties of a 4340 steel coated with Commonoy 88 alloy, applied by HVOF thermal spray, Surface and Coatings Technology, 140(2), 128-135.
  • Charre, M. D., (2004). Microstructure of steel and cast irons, (Trans. J.H. Davidson), Springer-Verlag Berlin Heidelberg New York, p.417.
  • Buytoz, S., (2004). Investigation of mechanical behaviors of AISI 4340 steel after surface modification processes with nitruration and GTA welding method, PhD Thesis, Fırat Univ. Institute of Sciences, Elazığ, p.190.
  • Kesti, E., (2009). Investigation of the effects of C-4140 steel on the temperament of environment of microstructure and mechanical properties, PhD Thesis, Seljuk University Institute of Sciences, Konya.
  • Tüfenk E., (2012). Investigation of Austenitic Manganese Steels with Different Chemical Compositions after Heat treatment, Master Degree Thesis, Ondokuz Mayıs University Institute of Sciences, Samsun
  • Subramanyam, D.K., (2005). Austenitic Manganese Steels. ASM Handbook, Properties and Selection: Irons, Steels, and High Performance Alloys, ASM Int., the United States of America, Vol. 01, 1274-1302.
  • Nejat S., (1995). High manganese austenitic steels and their sources. Journal of Metal and Source, 66, 36-41.
  • Duflou, J., R., Vancza, J., Aerens, R. (2005). Computer Aided Process Planning for Sheet Metal Bending: A State of the Art, Computers in Industry, 56, 747–771.
  • De Vin, L. J. (1994). Computer aided process planning for the bending of sheet metal components, Doctoral Dissertation, Enschede the Netherlands, ISBN 90-9007217-9.
  • De Vin, L. J., Streppel, A.H., Kalsi, H. J. J., Singh, U.P. (1995). Sensitivity analysis for air bending, Proceedings of the 3rd International Conference on Sheet Metal, ISBN: 0-9527664-0 X, 221–230.
  • De Vin, L. J., Streppel, A.H., Lutters, D. Kals, H.J.J. (1994). A process model for air bending in CAPP applications, Proceedings of the 2nd International Conference on Sheet Metal, ISBN: 1-85923-025-3, 17–28.
  • Lutters, D., Streppel, A.H., Kals, H.J.J. (1997). Adaptive press brake control in air bending, Proceedings of the 5th International Conference on Sheet Metal, ISBN: 1- 85923-072-5, 471–480.
  • Ötü, R., Demirci, H. İ. (2013)., Farklı Bükme Yöntemleri Uygulanarak V Bükme Kalıplarında AA 5754-O Sac Malzeme ile Elde Edilen Numunelerin Geri Esneme Miktarının Tespiti, Makine Teknolojileri Elektronik Dergisi, 10 (3), 27-42.
  • Tekiner, Z., (2004). An experimental study on the examination of springback of sheet metals with several thicknesses and properties in bending dies, Journal of Materials Processing Technology, 145, 109–117.
  • Özdemir, M., Gökmeşe, H., Dilipak, H., Yılmaz, V. (2104). Farklı ısıl işlemlerin 16Mo3 (1.5415) sac malzemenin ileri-geri esneme miktarına etkisinin deneysel ve mikroyapısal olarak incelenmesi, Akademik Platform ISITES 2014 Sempozyumu Karabük, (pp.148-155).
  • Tekaslan, Ö., Şeker, U. 2009. “Pirinç sac malzemelerin geri esneme miktarlarının tespiti”, 5. Uluslararası İleri Teknolojiler Sempozyumu (IATS’09).
  • Durgun, I., Yigit, K., Aydin, H., & Bayram, A. (2017). “Investigation of Mechanical Properties of Bismuth and Stann Mold Alloys Employed in Metal Sheet Forming Molds”, Uludağ University Engineering Faculty Journal, 22(3), Number 3, 11-20, DOI: 10.17482/uumfd.364084.
  • Adıyaman, O., (2019). Investigation of Manufacturability of Sheet-Metal Punches Produced by Manganese Steel, International Engineering and Science Symposium, 20-22 June, Siirt/Turkey, (pp.794-811).
  • Adıyaman, O. Kilic ,M. Yakut, R. (2021). Investigation of time-production performance of punch and dies produced from manganese steel material by casting method, International Symposium of Scientific Research and Innovative Studies, 22-25 February, Bandirma/Turkey, (pp. 215-226).
  • Adıyaman, O. Kilic, M. Yakut, R. (2021). Manganli çelikten döküm yöntemi ile üretilen bükme kaliplarinin aşinma daranişlarinin incelenmesi, International Symposium On Engineering, Natural And Social Sciences, ISENS-21, 25-28 November 2021 Batman/Turkey, (pp.110-117).
  • CKB Makine Kalip. Retrieved June 24, 2022, from http://www.ckbmakina.com.tr/?products
  • Sandvik Coromant. Retrieved June 24, 2022, from www.sandvik.coromant.com/tr, solutions for automotive components
  • Korloy. Retrieved June 24, 2022, from www.korloy.com/tr/download/cata.do
  • ISO Online Browsing Platform (OBP). Retrieved June 24, 2022, from www.iso.org/obp/ui/#iso:std:iso:8688:-1:ed-1:v1:en.do
  • Ulutan, M., Çelik, O., Gasan, H., Er, Ü. (2010). Effect of Different Surface Treatment Methods on the Friction and Wear Behavior of AISI 4140 Steel, Journal of Materials Science & Technology,, 26(3), 251-257.
  • Elbah, M., Yallese, M., Aouici, H., Mabrouiki, T. (2013). Comparative assessment of wiper and conventional ceramic tools on surface roughness in hard turning AISI 4140 steel, Measurement, 46, 3041–3056.
  • Khrais, S.K., Lin Y.J. (2007). Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel, Wear, 262, 64–69.
  • Aslan, E., Camuşçu, N., Birgören, B. (2007). Design optimization of cutting parameters when turning hardened AISI 4140 steel (63 HRC) with Al2O3 + TiCN mixed ceramic tool, Materials and Design, 28, 1618–1622.
  • Özler, L., Tosun, N., İnan, A. (2000). Investigation of Surface Roughness in Hot Machining of Austenitic Manganese Steel, Turk J Engin Environ Sci, 24, 287-296.
  • Kıyak, M., Uysal, A., Çakır, O., Altan, E. (2012). Tool life in orthogonal turning of high manganese steel with rounded hard metal tools, 3 National Machining Symposium, (pp. 496-502).
  • Demir, B. (2004). Examination of double-phase steel producibility from Ç4140 steel”, Technology, 4(1), 121-127.
There are 36 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Articles
Authors

Oktay Adıyaman 0000-0002-2674-3836

Project Number Btübap-2018-Tek-1
Publication Date December 30, 2022
Submission Date June 27, 2022
Published in Issue Year 2022 Volume: 6 Issue: 2

Cite

APA Adıyaman, O. (2022). Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability. International Journal of Innovative Engineering Applications, 6(2), 276-285. https://doi.org/10.46460/ijiea.1136221
AMA Adıyaman O. Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability. IJIEA. December 2022;6(2):276-285. doi:10.46460/ijiea.1136221
Chicago Adıyaman, Oktay. “Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability”. International Journal of Innovative Engineering Applications 6, no. 2 (December 2022): 276-85. https://doi.org/10.46460/ijiea.1136221.
EndNote Adıyaman O (December 1, 2022) Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability. International Journal of Innovative Engineering Applications 6 2 276–285.
IEEE O. Adıyaman, “Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability”, IJIEA, vol. 6, no. 2, pp. 276–285, 2022, doi: 10.46460/ijiea.1136221.
ISNAD Adıyaman, Oktay. “Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability”. International Journal of Innovative Engineering Applications 6/2 (December 2022), 276-285. https://doi.org/10.46460/ijiea.1136221.
JAMA Adıyaman O. Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability. IJIEA. 2022;6:276–285.
MLA Adıyaman, Oktay. “Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability”. International Journal of Innovative Engineering Applications, vol. 6, no. 2, 2022, pp. 276-85, doi:10.46460/ijiea.1136221.
Vancouver Adıyaman O. Investigation of Press Brake Punches and Dies Produced by Casting Method and From Manganese Steel Material in Terms of Machinability. IJIEA. 2022;6(2):276-85.