Şase yorulma parçalarından olan motor beşiğinin alüminyum ekstrüzyon metodu ile tasarımı ve kaynak edilmesinin incelenmesi
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Date
2021-06-07
Authors
Nişancı, Dilek Şengül
Journal Title
Journal ISSN
Volume Title
Publisher
Bursa Uludağ Üniversitesi
Abstract
Alüminyum, 1824 yılında Danimarkalı profesör, fizikçi ve kimyager Hans Christian Ørsted tarafından ortaya çıkarıldığından beri giderek popülerliğini arttırmış kimyasal elementtir. Günümüzde ise ağırlıklı olarak otomotiv, inşaat, savunma sanayi gibi sanayilerde kullanılmasının yanı sıra, farklı tüm sanayi dallarında da birçok avantajlı yönünden dolayı dikkat çeken bir malzeme olduğu bilinmektedir. Alüminyum malzemesi endüstri kullanımına uygun olup, tedariği oldukça kolay, geri dönüştürülmesi yüksek şekillendirilmeye elverişli ve çevreci bir malzemedir. Geliştirilmiş yüksek mukavemetli çeliklerin rakip malzemeleri arasında yer alan alüminyumun birçok üretim metodu bulunmaktadır. Alüminyumun sıkça kullanıldığı üretim metotlarından da biri olan ekstrüzyon prosesi sayesinde alüminyum alaşımlarının kolayca ekstrüzyon ile üretilmesi ve ışıl işlemlerle mukavemetinin arttırılabilmesi sağlanabilmektedir. Bu çalışmada, Almanya merkezli araç üreticisi bir firmanın, M2 sınıfına yönelik ürettiği elektrikli taşıtında prototip seviyesinde kullanılması için geliştirilmiş alüminyum motor beşiğinin, ekstrüzyon üretim yöntemiyle imal edilmesi ve doğrulanması adına AR-GE süreçleri aktarılmıştır. Mevcut çelik motor beşiğinin montaj yerlerinin ve paket hacminin sabit tutularak CATIA programı ile 3D modellenmesi, HyperWorks yazılımı ile statik analizinin yapılarak tasarımının dondurulması, ekstrüzyon ile üretildikten sonra ise CMT Robotu ile kaynaklanmadan önce kupon bazlı kaynak çalışmaları yapılmıştır. Tez sonunda ise çelik motor beşiğinin alüminyum ekstrüzyon yöntemiyle geliştirilmesiyle % 43,76 ağırlık kazancı sağlanmıştır. Tüm bunların yanı sıra müşteri mühendislik isterlerini sağlayan bir motor beşiği elde edilmiştir. Tez, 1501 Sanayi Ar-Ge Projeleri Destekleme Programınca 3181441 Proje Numarası altında TÜBİTAK tarafından 2019-2020 yıllarında desteklenmiş ve başarıyla tamamlanmıştır.
In 1824 by Danish professor, physicist, and chemist Hans Christian Ørsted was discovered aluminum which is a chemical element since that day aluminum has grown in popularity. Today, all manufacturer and market accepts and aspects that the aluminum have many advantage so result of that as well as mainly sectors used aluminum to as critical construction solutions such as automotive, construction, and even aviation industry Aluminum material is a chemical element which suitable for industrial use also has easy accessibility to supply, highly recyclable rate skills, and most of all environmentally friendly material when considering today's global warming situation. The aluminum material can produce many production methods, besides aluminum is a very competitive material, hence aluminum is preferable as much as to advanced highstrength steels. Ability to the extrusion process, which is one of the selected production methods to aluminum, aluminum alloys can be easily produced by extrusion progress. After the extrusion step, the heat treatment process can be increased the strength value.In this study, In this thesis, R&D activities were be presented/shared knowledge the electric vehicle for one of the Germany-based vehicle manufacturer company for the M2 class steel engine cradle about converting to new aluminum extrusion design. At the end of the development workflow, the new extruded aluminum engine cradle prototype was evaluated/performed by vehicle manufacturing company.The new aluminum design of the engine cradle's 3D modeling was created on the CATIA platform considering the first mounting locations and package volume of the target steel engine cradle. After that static analysis ran to the aluminum design with HyperWorks software, and coupon-based welding studies applied through using to CMT Robot. As a result, 43.76 % weight reduction was achieved. All, customer engineering and requirements were also provided. The thesis was funded and successfully completed in 2019-2020 under the Project Number 3181441 by the TÜBİTAK 1501 Industrial R&D Projects Support Program.
In 1824 by Danish professor, physicist, and chemist Hans Christian Ørsted was discovered aluminum which is a chemical element since that day aluminum has grown in popularity. Today, all manufacturer and market accepts and aspects that the aluminum have many advantage so result of that as well as mainly sectors used aluminum to as critical construction solutions such as automotive, construction, and even aviation industry Aluminum material is a chemical element which suitable for industrial use also has easy accessibility to supply, highly recyclable rate skills, and most of all environmentally friendly material when considering today's global warming situation. The aluminum material can produce many production methods, besides aluminum is a very competitive material, hence aluminum is preferable as much as to advanced highstrength steels. Ability to the extrusion process, which is one of the selected production methods to aluminum, aluminum alloys can be easily produced by extrusion progress. After the extrusion step, the heat treatment process can be increased the strength value.In this study, In this thesis, R&D activities were be presented/shared knowledge the electric vehicle for one of the Germany-based vehicle manufacturer company for the M2 class steel engine cradle about converting to new aluminum extrusion design. At the end of the development workflow, the new extruded aluminum engine cradle prototype was evaluated/performed by vehicle manufacturing company.The new aluminum design of the engine cradle's 3D modeling was created on the CATIA platform considering the first mounting locations and package volume of the target steel engine cradle. After that static analysis ran to the aluminum design with HyperWorks software, and coupon-based welding studies applied through using to CMT Robot. As a result, 43.76 % weight reduction was achieved. All, customer engineering and requirements were also provided. The thesis was funded and successfully completed in 2019-2020 under the Project Number 3181441 by the TÜBİTAK 1501 Industrial R&D Projects Support Program.
Description
Keywords
Alüminyum, Ekstrüzyon, Motor beşiği, Tasarım, Ürün geliştirme, Ağırlık kazancı, CMT kaynağı, Aluminium, Aluminum, Extrusion, Engine cradle, Subframe, Design, Development, Weight reduction, CMT welding
Citation
Nişancı, D. Ş. (2021). Şase yorulma parçalarından olan motor beşiğinin alüminyum ekstrüzyon metodu ile tasarımı ve kaynak edilmesinin incelenmesi. Yayınlanmamış yüksek lisans tezi. Bursa Uludağ Üniversitesi Fen Bilimleri Enstitüsü.