Çalışmada, DC01 çelik alaşımı sac malzemenin Artışlı Şekillendirme Yöntemi (AŞY) ile biçimlendirilmesindeyağlama elemanının performansını araştırmaya odaklanılmıştır. Bilindiği üzere AŞY’nde, işlemin ısı kaynağısürtünmedir. Takım-sac malzeme temas alanı ile temas alanının sabit kaldığı durumlarda devir sayısısürtünme ısısını kontrol etmektedir. Yağlama elemanlarının AŞY ile biçimlendirilen ürünün kalitesine etkisiniaçıklamak için çalışmada ayrıca bahsi geçen iki parametrenin de ürün kalitesine etkileri incelenmiştir.Çalışmada, dört farklı duvar açısına sahip kesik koni formu AŞY ile işlenmiş ve devir sayısı, takım çapı veyağlama elemanı deney değişkeni olarak belirlenmiştir. % incelme miktarı ve geometrik tamlık performansölçütü olarak belirlenmiştir. Üretilen parçaların CAD verilerinin elde edilebilmesi için 3D lazer taramayöntemi kullanılmış ve veriler üzerinde ürünlerin duvar açıları ve kalınlıkları ölçülmüştür. Hedef geometrininduvar açısı ile ürünün duvar açısı arasındaki fark geometrik tamlık, sac malzemenin ilk ve son kalınlıklarıarasındaki fark ise % incelme miktarı olarak tanımlanmıştır. Deneyler sonuçları, işlem sıcaklığının düşükolduğu şartlarda yağlama özelliği daha iyi olan yağlama elemanının hem % incelme hem de geometrik tamlıkbakımından daha başarılı sonuçlar verdiğini göstermiştir.
Extended abstract The aim of present study focuses on investigating the performance of lubricants used during Incremental Sheet Metal Forming (ISF) process of DC01 steel sheet alloys. It is known that the source of process temperature is friction in ISF operations and toolsheet metal contact area and spindle speed when the area is constant during the operation control friction temperature. In an attempt to explain effects of lubricants on the quality formed by ISF method, also influence of the mentioned two parameters on product quality were investigated. In this study, the truncated coni with four different wall angle was formed by ISF. Tool diameter, spindle speed, lubrication type were set as variables of experiments. Thinning % and geometrical accuracy were defined as performance criteria. The CAD data of formed parts were obtained by 3D laser scanning and used to measure wall angle and thickness. The difference between wall angles of target geometry and formed parts was defined as geometrical accuracy and difference between the initial and final thicknesses of sheet metal is specified as thinning %. In the present study, three different lubricants (boron oil and water-soluble drawing and spinning oilRenol EP/AC and water-insoluble drawing and spinning oil- Drawtex AC), tool diameter (Ø5 mm, Ø 10 mm and Ø 20 mm) and spindle speeds ( 250 rpm, 500 rpm, 1000 rpm) were used. Defect-free samples could be formed using all parameters except the conditions used the smallest tool diameter and water-soluble drawing, and spinning oil. The main findings of this study are as follows. In the first zone where forming begins, bending occurred instead of incremental sheet metal forming and also thinning do not observed in the mentioned zone. It is confirmed that, the boron oil has the best cooling effect when the water-insoluble drawing and spinning oil has the best lubrication effect. It is clear that, tool/sheet metal contact area increased with increasing tool diameter and forming wall angle. On the other hand, the ratio of feed-rate in other words forming speed to spindle speed is defined as speed factor in the literature. The experimental results showed that, friction temperature generated during incremental sheet metal forming process increased with the decreasing speed factor. Also, better geometric accuracy and thinning values was obtained with decreasing speed factor. On the other hand, water-insoluble drawing and spinning oil has the best lubrication properties gave the better result in the conditions used low process temperatures and small tool/sheet metal contact area. The optimum result was determined with watersoluble drawing and spinning oil when the tool diameter increased. Moreover, it is observed that, the thinning % was reduced with decreasing tool diameter. Also, geometric accuracy was decreased when the mentioned lubricant was used.
