Researcher:
Güzel, Birhan Ufku

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Master Student

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Birhan Ufku

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Güzel

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Güzel, Birhan Ufku

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    Improving cycle time in sculptured surface machining through force modeling
    (Elsevier, 2004) Budak, E.; Department of Mechanical Engineering; N/A; Lazoğlu, İsmail; Güzel, Birhan Ufku; Faculty Member; Master Student; Department of Mechanical Engineering; College of Engineering; Graduate School of Sciences and Engineering; 179391; N/A
    In this paper, an enhanced mathematical model is presented for the prediction of cutting force system in ball end milling of sculptured surfaces. This force model is also used as the basis for off-line feed rate scheduling along the tool path in order to decrease the cycle time in sculptured surface machining. As an alternative for setting a constant feed rate all along the tool path in rough machining of sculptured surfaces, resultant cutting forces are aimed to be kept under a pre-set threshold value along the tool path by off-line scheduled piecewise variable feed rates. In this paper, it is shown that machining time, depending on complexity of sculptured surfaces, can be decreased significantly by scheduling feed rate along the tool path. The model is tested under various cutting conditions and some of the results are also presented and discussed in the paper.
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    Increasing productivity in sculpture surface machining via off-line piecewise variable feedrate scheduling based on the force system model
    (Elsevier Sci Ltd, 2004) N/A; Department of Mechanical Engineering; Güzel, Birhan Ufku; Lazoğlu, İsmail; Master Student; Faculty Member; Department of Mechanical Engineering; Graduate School of Sciences and Engineering; College of Engineering; N/A; 179391
    Sculpture surface machining is a critical process commonly used in various industries such as the automobile, aerospace, die/mold industries. Since there is a lack of scientific tools in practical process planning stages, feedrates for CNC machining are selected based on the trial errors and previous experiences. In the selections of the process parameters, production-planning engineers are conservative in order to avoid undesirable results such as chipping, cutter breakage or over-cut due to excessive cutter deflection. Currently, commonly used CAD/CAM programs use only the geometric and volumetric analysis, but not the physics of the processes, and rely on experience based cutting tool database and users' inputs for selection of the process parameters such as feed and speed. Usually, the feeds and cutting speeds are set individual constant values all along the roughing, semi-finishing, and finishing processes. Being too conservative and setting feedrate constant all along the tool path in machining of sculpture surfaces can be quite costly for the manufacturers. However, a force model based on the physics of the cutting process will be greatly beneficial for varying the feedrate piecewise along the tool path. The model presented here is the first stage in order to integrate the physics of the ball-end milling process into the selection of the feeds during the sculpture surface machining. Therefore, in this paper, an enhanced mathematical model is presented for the prediction of cutting force system in ball end milling of sculpture surfaces. This physical force model is used for selecting varying and 'appropriate' feed values along the tool path in order to decrease the cycle time in sculpture surface machining. The model is tested under various machining conditions, and some of the results are also presented in the paper. (C) 2003 Elsevier Ltd. All rights reserved.
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    An enhanced force model for sculptured surface machining
    (Taylor and Francis inc, 2004) N/A; Department of Mechanical Engineering; Güzel, Birhan Ufku; Lazoğlu, İsmail; Master Student; Faculty Member; Department of Mechanical Engineering; Manufacturing and Automation Research Center (MARC); Graduate School of Sciences and Engineering; College of Engineering; N/A; 179391
    The ball-end milling process is used extensively in machining of sculpture surfaces in automotive, die/mold, and aerospace industries. in planning machining operations, the process planner has to be conservative when selecting machining conditions with respect to metal removal rate in order to avoid cutter chipping and breakage, or over-cut due to excessive cutter deflection. these problems are particularly important for machining of sculptured surfaces where axial and radial depths of cut are abruptly changing. This article presents a mathematical model that is developed to predict the cutting forces during ball-end milling of sculpture surfaces. the model has the ability to calculate the workpiece/cutter intersection domain automatically for a given cutter path, cutter, and workpiece geometries. in addition to predicting the cutting forces, the model determines the surface topography that can be visualized in solid form. Extensive experiments are performed to validate the theoretical model with measured forces. for complex part geometries, the mathematical model predictions were compared with experimental measurements.