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Öğe Adaptation of tilt adjustment and tracking force automation system on a laser-controlled land leveling machine(Elsevier Sci Ltd, 2018) Irsel, Gurkan; Altinbalik, M. TahirThis study is about the mechanization and automation works carried out to improve the operational efficiency of the laser-controlled land leveling machines and to design a more precise, ergonomic, economical and reliable system. At first, the existing laser-controlled leveling shovel has been redesigned through a mechanical design thus being adapted to automation. The mechanical structure was driven by the hydraulic system and the hydraulic system was controlled by the PLC. This new design consists of blade tilt adjustment automation system, track automation system, and maximum load protection system. With its new design, the machine can level out harder lands by less number of repetitions and less fuel consumption with a gradient precision of 0.05 degrees. After the design the time saving of 80% and the fuel saving of 85% has been achieved for the surfaces with the same area and approximately 10 L of fuel savings per acre has been performed. The new shovel system has been enabled to carry 1.3 times more soil for the same slope and also, just this modified machine can be used instead of using 3 separate land leveling machines for 3 different operations. Moreover, the requirement for land leveling in both directions has been avoided in leveling out narrow areas, especially on highway buildings.Öğe ANALYSIS OF AXLE SHAFT FATIGUE FAILURE AND ANTI-FATIGUE SYSTEM DESIGN(Lublin Univ Technology, Poland, 2017) Irsel, GurkanIn this study, an axle shaft subjected to static deformation and fatigue damage was considered by using computer-aided engineering. This shaft system was modeled with CATIA and subjected to dynamic fatigue analyses with Ansys workbench. The damaged fracture surfaces of the shaft have been examined. Thus, the fatigue and damage was revealed in greater detail. For the present system, a design with a minimum cost, short production process, minimum weight was sought together with methodical construction principles. By means of CATIA and ANSYS, the product development design with reasonable tension and deformation values was formed for endless life fatigue. A design was produced in a short space of time with the help of 2D CATIA drawings and field tests were carried out. The design was used through 560.000 cycles and damage was not observed.Öğe Bevel Gears Strength Calculation: Comparison ISO, AGMA, DIN, KISSsoft and ANSYS FEM Methods(Chinese Soc Mechanical Engineers, 2022) Irsel, GurkanGear strength calculation must be done in an appropriate and productive way to develop a strong and compact movement transmissions systems efficiently. In this research, the advantages and disadvantages of the calculation methods and the results of the calculation on a sample application are compared by referencing DIN 3991 method solution. Manual solution is an impractical and error-prone method. A max 27.5 % difference was found between ISO and AGMA analytical results. There is also a 17.3 % difference between KISSsoft solutions of the same methods. The KISSsoft solution gives immediate results in the event of changing different modules and revolutions. Modeling and mesh studies are required in ANSYS solution. Mesh affects the Ansys solution directly. There is 7 % difference between the Ansys FEM and KISSsoft (DIN) solutions. However, ANSYS enables the calculation in non-standard gears and modified gears. In this study, current gear calculation methods are presented, compared and evaluated in detail on an application.Öğe COMPUTER AIDED ADAPTIVE SYSTEM DESIGN WITH ENGINEERING SYSTEMATICS AND MANUFACTURING(Lublin Univ Technology, Poland, 2017) Irsel, GurkanThis research practically discusses and presents the stages of design process in product development. Design process was realized through CATIA. The product developed is an agricultural device called as disc harrow. Therefore, agricultural details are presented together with machine design. A roller system is added to disc harrow in this study. Thus; the current system and the additional roller system are discussed with the principles of methodological construction and design objectives are defined. Both the current system and the additional roller system are designed in parallel with these objectives. Structural stress analysis is performed at different kinetic positions of the disc harrow connection of the roller system. System design is achieved by considering the feedback from such analyses and design objectives. The hereby design is obtained. The additional roller system is mounted and field survey is carried out. Contribution of the roller to disc harrow process, defined design objectives, ratio of the realization of design objectives and results of stress analyses are evaluated.Öğe Design and Implementation of Low-Cost Field Crop Sprayer Electronic Flow Control System(Gazi Univ, 2021) Irsel, GurkanThe purpose of this research is to present the designs required and methodology of prototype production to control electronically a mechanical-controllable system on a case study. The system under consideration is a field crop sprayer. The reason for the investigation of this system is operator exposure to the harmful chemical and inefficiency of flow control. It is necessary to precisely start and end the chemical flow at the requested location, to close a certain part of the spraying line, and to prevent overdosing during the pulverization. An Arduino system was designed to control a precise electronic flow system. In this regard, Mechanical flow-control valves are equipped with 16 bar pressure-resistant and chemical resistant solenoid valves. Designs were produced and prototypes were presented. Low-cost sprayer control systems (SCS) chemical losses were reduced by 6% to 20%. The ergonomic design increased the productivity of the operator. Moreover, this system reduced fuel consumption by 2% to 6%. It is 40% more economical than existing systems. As a result, productive electronic control was achieved in the field crop sprayer.Öğe Design of a precision planter chassis using computer-aided engineering and experimental validation(Sage Publications Ltd, 2023) Irsel, GurkanThe application of X-section beams in the modular and strength-based design of a precision planter chassis was investigated numerically and experimentally in a case study. This study deals with the feasibility of a special section design with a systematic engineering approach. Mechanical tests were performed for the beam evaluated in a mounting system. The X-section beam model and the mounting elements on this beam were created using computer-aided engineering software, and the compatibility of the design with the mass criterion was investigated. This model was edited as a 2D and 3D mixed model and analyzed with the finite element method to analyzing studies of the system. Stress measurement was conducted using strain gauges at specified points in the system whose prototype was produced. These strain data were processed with nCode DesignLife software, and nonlinear FEA analyses were validated using these stress measurements. The fatigue damage of the X-section beam under dynamic loading conditions was investigated using the FE model solution and experimental measurement data (CAE-based fatigue analysis) with nCode software. The X-section beam design adopted a multiple-objective genetic algorithm technique for optimization by means of ANSYS. The maximum stress value was 121.83 MPa, and a 7.77 kg material was saved correlated to the prototype with the help of optimization solved 400 iterations. It has been determined that the X-section beam is safe by 1.06 x 10(6) cycles under these loading conditions and can carry a load of 1600 kg. The X-section beam can be successfully applied in similar systems owing to its assemblability and functionality.Öğe Effects of modification on the strength-weight ratio of standard bevel gears(Taylor & Francis Inc, 2022) Irsel, GurkanBecause of the current rapid technological progress, in addition to achieving increased speed and momentum in machine, transmitting more power in a low-noise, lightweight, safe, and economical manner and saving material in gears is crucial. For this purpose, modified bevel gears are common. Therefore, this study investigates bevel gear profile modifications focusing on strength and raw material saving. Herein, three modification designs (Modifications I-III) were modeled using CATIA software. Finite element analysis (FEA) and experimental tests were performed to investigate the effect of the proposed modifications on the gear's strength. Design and analysis procedures of the modifications were presented. Prototypes of the modified gear pairs were fabricated and subjected to strength and wear tests using a dynamic test device. The fatigue life of each gear pair was determined using nCode software. Modification II reduced the gear root stress by 3.98% relative to the original gear pair. Modification III resulted in 37.30% material saving, accompanied by 6.74% increase in contact stress. No fatigue damage was detected in either modification gear pair. The FEA results were compatible with the analytical, i.e., KISSsoft simulation, and experimental results; furthermore, FEA was found to be advantageous in terms of time and test costs in gear modification. Based on the obtained results for the three modifications, the Modification II gear pair is recommended for mass production.Öğe Experimental, analytical, and numerical investigations on the flexural and fatigue behavior of steel thin-walled X-section beam(Sage Publications Ltd, 2022) Irsel, GurkanThin-walled hollow shapes are of great interest in many industries with weight constraints, due to their availability, low price, and strength-to-weight ratio. This paper presents the development, calculation, and production of a thin-walled X-section beam design with a unique section geometry. This hollow X-section beam geometry is a beam that has been developed to use shape-connected jaws on the beam and to use less bolts and mounting elements, and to easily change the positions of the parts mounted on the beam. The bending strength of this unique beam section was investigated, and the fatigue damage of the beam was also handled with technological methods. Using both experimental stress measurements and finite element solution, the static and fatigue strength of the beam were calculated with computer-aided engineering software. The FEM solution was performed nonlinearly by defining the linear elastic and plasticity properties of the material. Validation studies were carried out in the laboratory using three-point and four-point bending tests. These traditional experiments were supported by strain gauge technology that measures strain with 0.05% accuracy. The weight and bending strength of the X-section beam were compared with the hollow section square beam. X-section beam (S355J0H) has 13% lower bending strength than 120 x 120 x 8 mm (S355J0H) beam; however, it is 37% lighter. ANSYS-analytical test results of difference are 3.95%, and ANSYS-experimental test results of difference are 0.85%. Experiments showed that a similar to 22% increase in strength is found in these corners depending on the production method. The fatigue behavior of the X-section beam was determined with the nCode DesignLife software using validated FEM solutions and fatigue curves of the materials. X-section beam developed for shape-connected assembly systems can be used especially in the formation of chassis with its superior assembly ability and bending strength, increasing functionality, and production speed.Öğe Investigation of combining the 304L and S355J2C+N materials with TIG welding in terms of microstructure and mechanical properties(Elsevier Sci Ltd, 2023) Kantur, Selin; Irsel, Gurkan; Guzey, Betuel NurThis study reports the investigation of the joining of S355J2C+N and 304L steels by the TIG welding method in terms of microstructure and mechanical properties. The effects of the microstructure of the heat-affected zones, the weld zone formed by the combination of two base metals with different superior properties, on the me-chanical properties were investigated. In the optical examination, optical microscope (OM), field emission scanning electron microscope (FESEM), energy dispersive X-ray spectroscopy (EDX), and X-ray diffraction (XRD) analyses were applied. Mechanical tests were carried out using tests such as microhardness (HV 0.1), bending, Charpy V-Notch impact, and tensile test. A microstructure was detected in the welded joint, which affects the mechanical properties. Grain size distribution in area fraction was determined from the EBSD maps of S355J2C+N steel, welded zone, heat affected zone (HAZ), and 304L. Average grain size of S355J2C+N base metal was 5.35 & PLUSMN; 1 & mu;m, mean grain size of 304L base metal was 35 & PLUSMN; 5 & mu;m, mean grain size for 304L HAZ was 41 & PLUSMN; 6 & mu;m, and for S355J2C+N HAZ 5.47 & PLUSMN; 1 & mu;m. Vickers microhardness values were measured as 222 & PLUSMN; 10 H V for 304 L base metal and 187 & PLUSMN; 10 HV for S355J2C+N base metal. The hardness of the weld center has the highest hardness and was determined as 302 & PLUSMN; 10 HV. In the tensile test, the highest tensile strength observed in the specimens extracted from the transverse direction is 534.88 & PLUSMN; 10 MPa. In the tensile test, a rupture occurred in S355J2C+N metal. In the bending test, the bending forces of 304L and S355J2C+N base metals were measured as 27.175 & PLUSMN; 4 kN and 28.480 & PLUSMN; 2 kN, respectively. The bending force of the transverse welded samples was 28.245 & PLUSMN; 2 kN, while the bending force of the longitudinal welded samples was 31.380 & PLUSMN; 2 kN. Weld ef-ficiency was obtained as 106%. Tungsten inert arc welding provided good properties such as strength, sealing, and toughness in the combination of stainless and carbon steel, and this welding method was determined to be suitable for the successful joining of these two dissimilar metals.Öğe Investigation of mechanical and microstructural properties in joining dissimilar P355GH and stainless 316L steels by TIG welding process(Elsevier Sci Ltd, 2023) Guzey, Betul Nur; Irsel, GurkanIn this study, the joining of high-temperature and pressure-resistant P355GH and austenitic stainless 316L steels by the Tungsten Inert Gas (TIG) welding method was investigated in terms of microstructure, mechanical properties, and weld efficiency. Comprehensive tests were carried out for the weld zone, heat-affected zones (HAZ), and base metals. In metallographic characterization research, optical microscope (OM), field emission scanning electron microscope (FESEM), energy dispersive X-ray spectroscopy (EDX/EDS), X-ray diffraction (XRD), and EBSD analyses were performed. Average grain size and IPF (Inverse Pole Figure) map were deter-mined from the EBSD analysis of P355GH steel, welded zone, heat-affected zones (HAZ), and 316L steel. Vickers microhardness, bending, Charpy V-Notch impact, and tensile tests were performed to determine the mechanical properties of the welded joint and the base materials. According to the EBSD results, the average grain size of the P355GH base metal was 5.13 +/- 1 mu m, the average grain size of the 316L base metal was 16.33 +/- 5 mu m, and the average grain size of the weld center was 10.09 +/- 6 mu m. As a result of XRD analysis, the delta ferrite phase was determined in the microstructure of the welding region. The highest Vickers microhardness value was deter-mined as 268 +/- 15 HV at the weld center. In the tensile test results, the highest tensile strength observed in the transverse weld joint was 593.92 +/- 06 MPa and rupture occurred in the 316L region. Bending forces were measured as 34.331 +/- 10 kN and 32.966 +/- 11 kN for transverse and longitudinal welded samples, respectively. The TIG welding process showed superior properties such as toughness, high plastic deformability, and high weld efficiency of 101.89% in the joining of 316L and P355GH materials.Öğe Redesigning and Manufacturing of a Land Levelling Shovel by Assembly Structural Stress Analysis(Hindawi Publishing Corporation, 2014) Altinbalik, Tahir; Irsel, GurkanThe aim was to redesign and manufacture of a shovel for a pull-type land levelling machine, which, in its present condition, is used to get easily damaged even under low loads. Firstly, the maximum pulling load affecting the levelling shovel was experimentally determined. Then, stable-shovel system with the bolt connection was replaced with a bearing-shaft connection system. In this way, the new shovel has gained a capability of making oscillation motion so that it can operate on sloped grounds. CATIA program was used in the design studies. The shovel system was investigated by assembly structural stress analyses. This new construction enabled the system to operate 3 times more securely at maximum stress conditions without changing the levelling shovel material. Thus, it is managed to prevent any possible damages that might occur due to maximum loading conditions of the system. Besides, displacements that occur on the shovel decreased at the rate of 90%.Öğe Strength-based design of a fertilizer spreader chassis using computer aided engineering and experimental validation(Sage Publications Ltd, 2021) Irsel, GurkanIn this research, stress measurement tests and advanced application algorithms based on computer-aided design and engineering (CAD and CAE) were developed and tested. The algorithm was put implemented through a case study on the strength-based structural design and fatigue analysis of a chassis. This algorithm consists of numerical and experimental methods and additionally includes material tests, three-dimensional CAD, a finite element method (FEM)-based analysis procedures, a structural optimization strategy, prototype production, stress tests, a fatigue analysis, and design verification procedures. In the optimization study targeting the optimum chassis weight/strength ratio, two chassis prototypes, with 8 mm and a 5 mm wall thicknesses, were manufactured to verify the structural analysis and experimental tests. As a result of the FEA analyses, for 20 kN, which is the target load value of the chassis, for chassis thicknesses t = 5 mm and t = 8 mm, the maximum tensile strength was obtained as 93 MPa and 83 MPa, respectively. Thus, the material gain of 35.85 kg mass was achieved, and chassis utilization efficiency was increased. This research provides a useful methodology for experimental and advanced CAE techniques, especially for further research on complex stress and deformation analysis of chassis that are desired to be of optimum weight/strength ratio.Öğe Strength-based design of a sunflower stalk cutter machine design using finite element analysis and experimental validation(Sage Publications Ltd, 2022) Irsel, GurkanIn this study, the total algorithm of the strength-based design of the system for mass production has been developed. The proposed algorithm, which includes numerical, analytical, and experimental studies, was implemented through a case study on the strength-based structural design and fatigue analysis of a tractor-mounted sunflower stalk cutting machine (SSCM). The proposed algorithm consists of a systematic engineering approach, material selection and testing, design of the mass criteria suitability, structural stress analysis, computer-aided engineering (CAE), prototype production, experimental validation studies, fatigue calculation based on an FE model and experimental studies (CAE-based fatigue analysis), and an optimization process aimed at minimum weight. Approximately 85% of the system was designed using standard commercially available cross-section beams and elements using the proposed algorithm. The prototype was produced, and an HBM data acquisition system was used to collect the strain gage output. The prototype produced was successful in terms of functionality. Two- and three-dimensional mixed models were used in the structural analysis solution. The structural stress analysis and experimental results with a strain gage were 94.48% compatible in this study. It was determined using nCode DesignLife software that fatigue damage did not occur in the system using the finite element analysis (FEA) and experimental data. The SSCM design adopted a multi-objective genetic algorithm (MOGA) methodology for optimization with ANSYS. With the optimization solved from 422 iterations, a maximum stress value of 57.65 MPa was determined, and a 97.72 kg material was saved compared to the prototype. This study provides a useful methodology for experimental and advanced CAE techniques, especially for further study on complex stress, strain, and fatigue analysis of new systematic designs desired to have an optimum weight to strength ratio.Öğe Study of the microstructure and mechanical property relationships of shielded metal arc and TIG welded S235JR steel joints(Elsevier Science Sa, 2022) Irsel, GurkanThis study reports the investigation of the microstructural and mechanical characterizations of low carbon steel EN10025 S235JR welded with tungsten inert gas welding (TIG or GTAW) and shielded metal arc welding (SMAW). TIG and SMAW microstructures in fusion regions were compared in this context, and their effect on mechanical properties was examined. Experiments were carried out using optical microscope (OM), scanning electron microscope (SEM), X-ray diffraction (XRD), and mechanical tests, such as tensile, vickers microhardness (HV 0.1), bending, and charpy V-Notch impact tests. In the optical investigation, the base metal's average grain size was measured as 12 +/- 2 mu m. After the TIG and SMAW processes, the average grain size in the HAZ was measured to be 20 +/- 3 mu m and 15 +/- 2 mu m, respectively. Therefore, the mechanical testing results were appropriately correlated with the microstructure analysis. The Vickers microhardness gradually increased from the base metal approaching the heat-affected zone for both welding methods. The highest hardness value was measured in the TIG welding center and was 430 +/- 12 HV. In the SMAW center, the maximum hardness was measured as approximately 230 +/- 5 HV, and the hardness of the base metal was approximately 120 +/- 8 HV. The microhardness in the TIG weld zone significantly increased because of the presence of delta-ferrite (delta-ferrite) and Widmansta center dot tten ferrite (WF) in the microstructure. Mechanical strength analysis showed that the ultimate tensile strength (UTS) of the specimen extracted from the longitudinal direction of the TIG weldment was 652 +/- 10 MPa and that the UTS of the SMAW weldment was 591.40 MPa. The bending test showed that the bending force of the specimen extracted from the longitudinal direction of the TIG weldment was approximately 57% higher than that of the SMAW weldment. Finally, TIG welding has superior properties in terms of strength, higher quality weld, and smooth weld bead appearances.
