Browsing by Author "Cogun, Can"

Now showing 1 - 16 of 16

Citation - WoS: 7
Citation - Scopus: 9
An experimental work on using conductive powder-filled polymer composite cast material as tool electrode in EDM
(Springer London Ltd, 2014) Yaman, Kemal; Çoğun, Can; Cogun, Can; 3837
This paper introduces the composite tool electrodes made of electrical conductive powder-filled polyester resin matrix material, providing promise for the electrical discharge machining (EDM) process. The dendrite-shaped copper powder, graphite powder, and their mixture were used as conductive fillers. Six different types of composite electrodes, namely, plain copper-polyester, pressed copper-polyester, furnaced copper-polyester, plain copper-graphite-polyester, pressed copper-graphite-polyester, and furnaced copper-graphite-polyester were prepared. It is found experimentally that increasing v (f) improved workpiece material removal rate, tool wear rate, relative wear, and electrical conductivity of electrodes. The pressed copper-polyester electrodes were found to be promising in the ED finishing of workpieces at low machining current settings. The practical applicability of the proposed composite electrodes in the industry was also illustrated.
Citation - WoS: 6
Citation - Scopus: 6
Design and implementation of an electrode feed rate control system in the electrochemical drilling process
(Springer Heidelberg, 2022) Ozerkan, Haci Bekir; Çoğun, Can; Cogun, Can; 3837
The interelectrode gap distance control is essential for preventing short circuit and spark discharge occurrences in the machining gap and ensuring a constant distance between the tool electrode (shortly electrode) and the workpiece throughout the electrochemical drilling (ECD) process. In this study, a gap distance control system was designed and implemented in the constructed ECD machine tool. The gap distance control strategy was based on the machining current's discrete measurement (in microsecond intervals) and changing the gap distance according to a set current value by feeding the electrode towards the workpiece or retracting it during the ECD process. The small diameter deep hole ECD experiments were conducted using 0.5 mm diameter side insulated tubular rotational electrodes with through-hole electrolyte flushing to drill Hadfield and AISI 1040 steels. The experimental results demonstrated the success of the developed control system in ECD operations yielding uniform hole geometries and smooth hole surfaces. The use of the control system eliminated the undesirable formations of spark discharges and short circuit pulses.
Citation - WoS: 7
Citation - Scopus: 7
Development and experimental investigation of electrochemical drilling method using rotary tube tool
(Gazi Univ, Fac Engineering Architecture, 2013) Ozerkan, H. Bekir; Çoğun, Can; Cogun, Can; 132262; 3837
In this study, a new hybrid electrochemical drilling (ECD) method, based on electrochemical machining in nonconventional machining processes, was developed. In the developed method, tube tool makes rotary motion together with inner through hole flushing. A small scale prototype ECD machine has been designed and manufactured to test the developed method. One of the important features of the new system is the regulation of tool feed rate using current feedback control. The Hadfield (manganese) steel, whose strain hardening behavior makes it very difficult to machine with conventional methods, and AISI 1040 steel, whose machinability is fairly good, were drilled using the prototype machine and results were compared. Workpiece material removal rate increased with the increasing machining voltage, tool rotational speed, electrolyte concentration and flushing pressure in both types of steels. Average radial overcut values increased with the rotational speed of the tool. The AISI 1040 steel hole geometries were regular than that of Hadfield steel. Experimental results showed that deep holes can be drilled successfully with the proposed hybrid ECD method.
Citation - WoS: 20
Citation - Scopus: 21
Effect of electrical discharge machining on dental Y-TZP ceramic-resin bonding
(Elsevier Ireland Ltd, 2017) Çoğun, Can; Rona, Nergiz; Yenisey, Murat; Esen, Ziya; Kucukturk, Gokhan; Gurun, Hakan; Cogun, Can; Esen, Ziya; 3837; 52373
Purpose: The study determined (i) the effects of electrical discharge machining (EDM) on the shear-bond strength (SBS) of the bond between luting resin and zirconia ceramic and (ii) zirconia ceramic's flexural strength with the three-point bending (TPB) test. Methods: Sixty 4.8 mm x 4.8 mm x 3.2 mm zirconia specimens were fabricated and divided into four groups (n = 15): SBG: sandblasted + silane, TSCG: tribochemical silica coated + silane, LTG: Er:YAG laser treated + silane, EDMG: EDM + silane. The specimens were then bonded to a composite block with a dual-cure resin cement and thermal cycled (6000 times) prior to SBS testing. The SBS tests were performed in a universal testing machine. The SBS values were statistically analyzed using ANOVA and Tukey's test. To determine flexural strength, sixty zirconia specimens were prepared and assigned to the same groups (n = 15) mentioned earlier. After surface treatment TPB tests were performed in a universal testing machine (ISO 6872). The flexural strength values were statistically analyzed using ANOVA and Tukey's test (a = 0.05). Results: The bond strengths for the four test groups (mean SD; MPa) were as follows: SBG (Control), 12.73 +/- 3.41, TSCG, 14.99 +/- 3.14, LTG, 7.93 +/- 2.07, EDMG, 17.05 +/- 2.71. The bond strength of the EDMG was significantly higher than those of the SBG and LTG (p < 0.01). The average flexural strength values for the groups SBG (Control), TSCG, LTG and EDMG were 809.47, 800.47, 679.19 and 695.71 MPa, respectively (p > 0.05). Conclusions: The EDM process improved the SBS. In addition, there was no significant adverse effect of EDM on the flexural strength of zirconia. (C) 2016 Japan Prosthodontic Society. Published by Elsevier Ltd. All rights reserved.
Citation - WoS: 26
Citation - Scopus: 29
Effect of powder metallurgy Cu-B4C electrodes on workpiece surface characteristics and machining performance of electric discharge machining
(Sage Publications Ltd, 2016) Çoğun, Can; Cogun, Can; Esen, Ziya; Esen, Ziya; Genc, Asim; Çoğun, Ferah; Cogun, Ferah; Akturk, Nizami; 3837; 52373
The main aim of this study is to produce new powder metallurgy (PM) Cu-B4C composite electrode (PM/(Cu-B4C)) capable of alloying the recast workpiece surface layer during electric discharge machining process with boron and other hard intermetallic phases, which eventually yield high hardness and abrasive wear resistance. The surface characteristics of the workpiece machined with a PM/(Cu-B4C) electrode consisted of 20 wt% B4C powders were compared with those of solid electrolytic copper (E/Cu) and powder metallurgy pure copper (PM/Cu) electrodes. The workpiece surface hardness, surface abrasive wear resistance, depth of the alloyed surface layer and composition of alloyed layers were used as key parameters in the comparison. The workpiece materials, which were machined with PM/(Cu-B4C) electrodes, exhibited significantly higher hardness and abrasive wear resistance than those of machined with the E/Cu and PM/Cu. The main reason was the presence of hard intermetallic phases, such as FeB, B4C (formed due to the boron in the electrode) and Fe3C in the surface layer. The improvement of the surface hardness achieved for steel workpiece when using PM/(Cu-B4C) electrodes was significantly higher than that reported in the literature. Moreover, the machining performance outputs (workpiece material removal rate, electrode wear rate and workpiece average surface roughness (Ra)) of the electrodes were also considered in this study.
Citation - WoS: 9
Citation - Scopus: 10
Effect of use of cu-cr p/m electrodes on machining performance of electric discharge machining
(Gazi Univ, Fac Engineering Architecture, 2015) Gulcan, Orhan; Çoğun, Can; Uslan, Ibrahim; Usta, Yusuf; Cogun, Can; 3113; 118190; 3837
In this study, the effect of use of Cu-Cr powder metal (P/M) electrodes on EDM performance outputs, namely material removal rate (MRR), electrode wear rate (EWR), mean and maximum roughness of machined surface (R-a and R-z) and workpiece surface recast layer thickness, was investigated experimentally. The Cu-Cr P/M electrodes produced at different mixing ratios, compacting pressures and sintering temperatures were used to machine SAE 1040 steel. The analyses performed have shown that the electrode material is deposited on to the work surface as a layer and the powder mixing ratio, the compaction pressure and sintering temperature affect the EDM performance outputs.
Citation - WoS: 11
Citation - Scopus: 12
Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM)
(Taylor & Francis inc, 2022) Çoğun, Can; Simsek, Ulke; Cogun, Can; Esen, Ziya; Esen, Ziya; 52373; 3837
The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal rate (MRR), low electrode wear rate (EWR), and relative wear (RW = MRR/EWR). In this study, the EDM performance outputs, namely, MRR and RW were experimentally investigated for electrolytic copper, CuCr1Zr (with and without aging treatment) and CuCo2Be alloy electrode materials for varying machining parameters. The performance outputs were affected by the electrode material and the applied aging treatment. The aged CuCr1Zr alloy electrodes had higher electrical conductivity and better machining performance than the as-received alloy. The CuCo2Be alloy electrodes exhibited moderate to high MRR; however, their RW was the highest. Although the electrolytic copper has moderate MRR performance compared to the investigated alloys, its low cost increased its performance index, making it a more suitable electrode material for EDM applications.
Citation - WoS: 12
Citation - Scopus: 11
ELECTROCHEMICAL SMALL DIAMETER DEEP HOLE DRILLING OF POWDER METAL STEEL
(Univ Zagreb Fac Mechanical Engineering & Naval Architecture, 2020) Ozerkan, Haci Bekir; Çoğun, Can; Cogun, Can; 3837
In this study, a new hybrid electrochemical drilling (ECD) method is proposed. The method makes use of a tubular tool capable of rotating and an electrolyte flushing through the inner hole at the same time. The designed and manufactured small size ECD machine's most important features are the regulation of the tool feed rate via current feedback control and the use of a rotating tubular tool with internal electrolyte flushing. The powder metal (PM) FLN2 4405 steel was drilled by using a brass tubular tool with various combinations of machining parameters such as machining voltage, electrolyte concentration and flushing pressure, and tool rotation speed. The machining performance outputs, namely, material removal rate (MRR), average radial overcut (RADOC), conicity (CO) and hole geometries were calculated and compared in different machining conditions. The results have shown that the aforementioned variables had a direct impact on the machining performance outputs in ECD. In all experiments, MRR increased with an in increase in machining voltage, tool rotational speed, electrolyte concentration and flushing pressure. RADOC values decreased with the rotational speed of the tool. The present study shows that deep holes with precise geometries and dimensions can be drilled successfully by employing the proposed hybrid ECD method. The method is economical and environmentally friendly since it requires low machining current values (0.1 to 0.7A) and a small amount of non-hazardous halide salt solutions instead of acidic solutions throughout the drilling process.
Citation - WoS: 1
The Entropy Method Integrated Rsm Model To Evaluate Hole Geometries in Electrochemical Blind Hole Drilling
(Taylor & Francis Ltd, 2025) Ayhan, Emre; Yurdakul, Mustafa; Cogun, Can; Ic, Yusuf Tansel
The electrochemical drilling (ECD) process enables the machining of conductive materials with a wide range of hardness, yield strength, and brittleness. In this study, the ECD experiments have been conducted on blind hole drilling in high-speed steel material using a tailor-made ECD machine. The hole geometries (cross-sectional profiles) at different machining parameters have been examined for the hole depth consistency (HDC), hole cross-sectional area (HCAC) and the hole profile length (HPLC) evaluation (response; output) metrics introduced. The relationships between the hole geometry evaluation metrics and machining parameters are obtained using the response surface method (RSM). Using the Entropy method, an optimisation model is also proposed to combine multiple responses into a single objective function. The effectiveness of the Entropy method is compared with the Analytical Hierarchical Process (AHP). The comparison showed that the Entropy model provides more robust and convenient results than the AHP approach.
Citation - WoS: 17
Citation - Scopus: 22
Experimental Investigation on Wire Electric Discharge Machining of Biodegradable AZ91 Mg Alloy
(Springer, 2021) Çoğun, Can; Urtekin, Levent; Ozerkan, Haci Bekir; Esen, Ziya; Cogun, Can; Genc, Asim; Esen, Ziya; Bozkurt, Fatih; 3837; 52373
The AZ91 magnesium alloy, used commonly as a biodegradable material in biomedical applications, is generally formed by conventional casting method (CCM) and high-pressure die casting method (HPDCM). The AZ91 alloys exhibit poor machinability with conventional chip removal methods since they degrade at elevated temperatures. In this study, the wire electric discharge machining (WEDM) was presented as a candidate process to machine the AZ91 alloy since no cutting stresses and plastic deformations were applied by the cutting tool to the part causing elevated temperatures. In this context, the WEDM machinability of the AZ91 alloy samples produced by cold chamber HPDCM and CCM at different process parameters, was experimentally investigated. The machining performance outputs (the machining current (I), the machining rate (MR), the average surface roughness (R-a), and surface topography) were found for the varying process parameters [pulse time (t(s)), pulse-off time (t(off)), dielectric flushing pressure (P-d), and wire speed (V-w)]. The present study revealed that the I and the MR were significantly dependent on the density, the porosity, and the micro structure of the samples, and the HPDCM samples gave the higher MR and the smoother surface than that of the CCM.
Citation - WoS: 34
Citation - Scopus: 40
Improvement of electric discharge machining (EDM) performance of Ti-6Al-4V alloy with added graphite powder to dielectric
(Assoc Mechanical Engineers Technicians Slovenia, 2015) Unses, Emre; Çoğun, Can; Cogun, Can; 3837
Ti-6Al-4V is a well-known Ti alloy widely used in the aerospace industry and belongs to the group of difficult-to-machine materials. It is less suitable for both conventional chip removal (machining) techniques and electric discharge machining (EDM). The very low material removal rate (MRR) of the Ti alloys during the EDM process causes prohibitively long machining durations. The goal of this study was to improve the EDM performance of the Ti-6Al-4V alloy by the addition of graphite powder into the kerosene dielectric liquid. The EDM performance was quantified by MRR, tool electrode wear rate (EWR), relative wear (RW), surface roughness and texture properties. The experiments conducted have shown that the use of graphite powder mixed with the kerosene dielectric (GPMKD) during machining considerably increases the MRR, improves the R-a and R-z(DIN) surface roughness and decreases the RW. 3D topographic views of the machined workpiece surfaces attained with GPMKD revealed uniformly distributed surface valleys and peaks over the surface and peaks with short arid round tops since the discharge energy of a spark is distributed over a large area at the machining gap. The experimental results strongly indicate the adaptability of the proposed technique to EDM die sinking and EDM drilling applications of the Ti-6Al-4V alloy in the aerospace industry. The ED machining performance of Ti-6Al-4V alloy using GPMKD is also compared to that of AISI 1040 steel, which is commonly used in EDM applications.
Citation - WoS: 15
Citation - Scopus: 15
Influence of welding on microstructure and strength of rail steel
(Elsevier Sci Ltd, 2020) Sarikavak, Yasin; Çoğun, Can; Turkbas, Osman Selim; Cogun, Can; 3837
In this study, metallurgical and mechanical aspects of cold flash butt welded rail joints were investigated. The relationship between the material characteristics and the distance to the fusion line were evaluated. Significant changes observed in grain size as it ranges 2-8 according to ASTM E 112. Hardness tests conducted and the average results of the rail head, web, and foot were recorded. According to the results, three different zones were identified including the fusion line, recrystallization zone, and transition areas. Tensile properties and strength characteristics have been investigated for the specified zones separately. Obtained experimental values were used as input parameters for the developed finite element model (FEM) to calculate stress distribution. The welded rail was subjected to realistic wheel load and stress distributions in weld were evaluated. The developed model has also been validated by comparing the theoretically obtained stress values with the experimental ones under various loading conditions. (C) 2020 Elsevier Ltd. All rights reserved.
Citation - WoS: 0
Citation - Scopus: 0
Machine Learning-Driven Approach for Reducing Tool Wear in Die-Sinking Electrical Discharge Machining
(Springer Heidelberg, 2025) Cogun, Can; Ayli, Ece
This study examines the use of machine learning (ML) techniques to optimize the basic machining parameters and protrusion dimensions that affect tool shape degeneration in die-sinking electric discharge machining (EDM). The primary objective is to decrease errors and enhance prediction and optimization effectiveness. This study introduces a completely novel tool geometry model aimed at minimizing tool shape degeneration, which, to our knowledge, has not been previously documented in the literature. Additionally, this research represents the first instance of employing ML techniques to generate data for addressing this specific type of problem, further advancing the field of die-sinking EDM. The pivotal machining parameters include discharge current, pulse time and machining depth. Three ML approaches are implemented in this investigation: Artificial Neural Network (ANN), Adaptive-Network-Based Fuzzy Inference System (ANFIS), and Support Vector Machine (SVM). In comparison with experimental outcomes, the ANN technique exhibited superior predictive ability with an coefficient of determination (R2) of 0.99985 and an Mean Relative Error (MRE) of 0.854%. Four distinct EDM machining scenarios are presented and machining parameters and protrusion dimensions are optimized using the ANN technique to decrease tool shape degeneration. Optimizing the machining parameters and diagonal dimensions of the protrusion substantially reduced tool shape degeneration. This research demonstrates the effectiveness of ANN in optimizing machining parameters and improving tool performance in die-sinking EDM. A significant reduction in total wear area of 66.7% was achieved with a considerably lower time cost through the optimized ANN network. While the study demonstrates promising results, its reliance on specific datasets for training may limit the generalizability of the model to broader machining scenarios.
Citation - WoS: 28
Citation - Scopus: 32
Performance and surface alloying characteristics of Cu-Cr and Cu-Mo powder metal tool electrodes in electrical discharge machining
(Taylor & Francis inc, 2016) Gulcan, Orhan; Çoğun, Can; Uslan, Ibrahim; Usta, Yusuf; Cogun, Can; 3113; 118190; 3837
The main objective of this study is to investigate the effect of Cu-Cr and Cu-Mo powder metal (PM) tool electrodes on electrical discharge machining (EDM) performance outputs. The EDM performance measures used in the study are material removal rate (MRR), tool electrode wear rate (EWR), average workpiece surface roughness (R-a), machined workpiece surface hardness, abrasive wear resistance, corrosion resistance, and workpiece alloyed layer depth and composition. The EDM performance of Cu-Cr and Cu-Mo PM electrodes produced at three different mixing ratios (15, 25, and 35wt% Cr or Mo), compacting pressures (P-c = 600, 700, and 800MPa), and sintering temperatures (T-s = 800, 850, and 900 degrees C) are compared with those machined with electrolytic Cu and Cu PM electrodes when machining SAE 1040 steel workpiece. Analyses revealed that tool materials were deposited as a layer over the work surface yielding high surface hardness, strong abrasion, and corrosion resistance. Moreover, the mixing ratio, P-c, and T-s affect the MRR, EWR, and R-a values.
Citation - WoS: 10
Citation - Scopus: 9
The effect of powder mixed and heated dielectric on drilling performance of electric discharge machining (EDM)
(Gazi Univ, Fac Engineering Architecture, 2016) Erdem, Oguz; Çoğun, Can; Cogun, Can; Urtekin, Levent; Ozerkan, H. Bekir; Uslan, Ibrahim; 3837
In this study, heated silicon oil with added carbon and starch powders was used as dielectric liquid, instead of common hydro-carbon based dielectrics, to obtain better hole surface quality with rotating brass tube electrode in electric discharge machining (EDM). The electro-rheometer tests were conducted to find out the suitable temperature and powder concentration values of the electro-rheological (ER) dielectric under the electric field. Higher workpiece material removal rates (MRR) was obtained in carbon powder added dielectrics than the starch powder added ones for rotating and non-rotating electrodes. The optical microscope observations of the machined hole surfaces indicated that the carbon powder added dielectrics reduced the diameter and depth of the discharge craters, thereby resulting in uniformly distributed and round top peaked surface topography. The starch powder addition to the carbon mixed dielectric further improved the surface quality for both rotating and non-rotating electrodes cases at 30 degrees C and 75 degrees C dielectric temperatures.
Citation - WoS: 6
Citation - Scopus: 6
Thermo-fluid multi-physics modeling and experimental verification of volumetric workpiece material removal by a discharge pulse in electric discharge machining process
(Iop Publishing Ltd, 2020) Erdem, Oguz; Çoğun, Can; Cogun, Can; Uslan, Ibrahim; Erbas, Murat; 3837
The volume of material removed from the workpiece by a pulse (V-v) in the electric discharge machining was quantitatively determined using a multi-physics simulation model in ANSYS CFX software. Electrical heating is used in the model to simulate the plasma channel formation by defining the boundary and time-controlled current density initial conditions. Time-dependent physical properties at plasma temperature were used to reflect the actual processing environment. The heat was transferred from the plasma channel to the workpiece by electrical heating from the electrode, and V(v)was calculated by means of the amount of heat transfer. The calculated V(v)values for AISI4140, Ti6Al4V and Inconel 718 workpieces were lower than the experimental results and the difference was observed to change between 38.3% and 46.9%.