Mechanical Engineering / Makina Mühendisliği
Permanent URI for this collectionhttps://hdl.handle.net/11147/4129
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Article Citation - WoS: 18Citation - Scopus: 20Cold Plate Enabling Air and Liquid Cooling Simultaneously: Experimental Study for Battery Pack Thermal Management and Electronic Cooling(Elsevier, 2023) Coşkun, Turgay; Çetkin, ErdalThe temperature of cells varies greatly during dis/charge while their performance and lifetime are greatly affected by this fluctuation. Elevated temperatures may yield battery fire due to thermal runaway as well they accelerate ageing and capacity fade of cells. Thermal management systems are a necessity for electric vehicles to extend the lifetime of battery cells and eliminate any fire risks, especially for fast dis/charging applications. Here, we document a hybrid cold plate with a working fluid(s) of sole air or liquid as well as both of them. Hybridization of air and liquid cooling promises to minimize energy consumption requirements during a charge/ discharge cycle by combining the benefits of both thermal management strategies if energy management is controlled accordingly. The temperature of each cell can be kept below 30 degrees C with the proposed hybrid cooling heat exchanger, and the temperature difference between the cells is reduced by 30 % relative to liquid cooling. The maximum temperatures are decreased by 18 % and 3 % in hybrid cooling when compared to air and water cooling, respectively. Furthermore, a step function combining various discharge rates (1C and 3C) was employed in experiments to mimic a realistic situation, i.e. variable C-rate rather than constant. The results show that the temperature of the battery cells can be kept below 30 degrees C with air cooling for variable discharge rate and the effect of contact resistance should not be overlooked for liquid cooling. Furthermore, the possible use of the proposed hybrid cold plates is surveyed in the cooling of electronic devices which produce more and continuous heat than cells. Therefore, three resistance heaters with a capacity of 50W are used in experiments as well. The results show that the proposed cold plates could be used in both electronics cooling and battery thermal management with a control algorithm to switch between sole working fluid and combination modes which could be developed based on the results of this paper.Article Citation - WoS: 5Citation - Scopus: 5Investigation and Validation of the Flow Stress Equation and Damage Model Parameters of an Electron Beam Melted Ti6al4v Alloy With a Martensitic Phase(Elsevier, 2023) Güden, Mustafa; Bin Riaz, Arslan; Toksoy, Ahmet Kaan; Yıldıztekin, Murat; Erten, Hacer İrem; Çimen, Gülden; Hızlı, BurakThe Johnson and Cook flow stress and damage model parameters of an electron beam melt (EBM)-Ti64 alloy composed of & alpha;' (martensite) and & alpha;+& beta; and an extruded-annealed conventional Ti64 alloy were determined experimentally. The validities of the determined flow stress equations and damage model parameters were then verified by the numerical simulations of the compression tests on the Body Centered Cubic lattices produced using the same EBM parameters with the solid EBM samples. In addition, a compression flow stress equation was extracted from the small-size test specimens (1 and 2 mm diameter) taken directly from the struts of the as-built lattices. The microscopic observations, XRD analyses and hardness tests confirmed the presence of & alpha;& PRIME; phase in the EBM solid samples and in the struts of the BCC lattices, which reduced the ductility of the EBM solid specimens and struts compared to the conventional Ti64. Furthermore, the partially melt particles on the surfaces of the struts acted as the stress concentration sides for micro-cracking; hence, the compression flow stresses of the struts were found to be significantly lower than those of the as-built EBM solid specimens. The flow stress equation derived from the struts predicted more accurately the compression behavior of the lattices. The compression tests and models showed that early damage formation in the lattices was noted to decrease the initial peak and post peak stresses. As with the experiments, the initial damage occurred in the models with the separation of the nodes at the lattice cell surface edges. This resulted in an abrupt reduction in the stresses after the peak stress. The numerical lattices without damage showed a localized lattice deformation at the mid-sections and the stress increased continuously as a function of normal strain.Article Citation - WoS: 9Citation - Scopus: 13Analysis of Adhesively Bonded Joints of Laser Surface Treated Composite Primary Components of Aircraft Structures(Elsevier, 2023) Martin, Seçkin; Nuhoğlu, Kaan; Aktaş, Engin; Tanoğlu, Metin; İplikçi, Hande; Barışık, Murat; Yeke, Melisa; Türkdoğan, Ceren; Esenoğlu, Gözde; Dehneliler, SerkanThe performance of the adhesively bonded aerospace structures highly depends on the adhesion strength between the adhesive and adherents, which is affected by, in particular, the condition of the bonding surface. Among the various surface treatment methods, as state of the art, laser surface treatment is a suitable option for the CFRP composite structures to enhance the adhesion performance, adjusting the roughness and surface free energy with relatively minimizing the damage to the fibers. The aim of this study is the validation and evaluation of the adhesive bonding behavior of the laser surface-treated CFRP composite structures, using the finite element technique to perform a conservative prediction of the failure load and damage growth. Such objectives were achieved by executing both experimental and numerical analyses of the secondary bonded CFRP parts using a structural adhesive. In this regard, to complement physical experiments by means of numerical simulation, macro-scale 3D FEA of adhesively bonded Single Lap Joint and Skin-Spar Joint specimens has been developed employing the Cohesive Zone Model (CZM) technique in order to simulate bonding behavior in composite structures especially skin-spar relation in the aircraft wing-box.Article Citation - WoS: 12Citation - Scopus: 12High Strain-Rate Deformation Analysis of Open-Cell Aluminium Foam(Elsevier, 2023) Mauko, Anja; Duarte, Isabel; Borovinšek, Matej; Vesenjak, Matej; Ren, Zoran; Sarıkaya, Mustafa; Güden, MustafaThis study investigated the high-strain rate mechanical properties of open-cell aluminium foam M-pore®. While previous research has examined the response of this type of foam under quasi-static and transitional dynamic loading conditions, there is a lack of knowledge about its behaviour under higher strain rates (transitional and shock loading regimes). To address this gap in understanding, cylindrical open-cell foam specimens were tested using a modified Direct Impact Hopkinson Bar (DIHB) apparatus over a wide range of strain rates, up to 93 m/s. The results showed a strong dependency of the foam's behaviour on the loading rate, with increased plateau stress and changes in deformation front formation and propagation at higher strain rates. The internal structure of the specimens was examined using X-ray micro-computed tomography (mCT). The mCT images were used to build simplified 3D numerical models of analysed aluminium foam specimens that were used in computational simulations of their behaviour under all experimentally tested loading regimes using LS-DYNA software. The overall agreement between the experimental and computational results was good enough to validate the built numerical models capable of correctly simulating the mechanical response of analysed aluminium foam at different loading rates. © 2023 The AuthorsArticle Citation - WoS: 1Citation - Scopus: 1Epoxy Matrix Nano Composites: Modulus, Strength and Ductility Enhancement Through Auxeticity of Α-Cristobalite Filler(Elsevier, 2023) Güden, Mustafa; Ülker, Sevkan; Movahedi, NimaThe negative Poisson's ratio (NPR) nano-size ?-Cristobalite particle/epoxy composites were prepared and tensile tested. The elastic modulus and strength of the composites were improved as the particle volume fraction increased from 0 to 0.02. Unlike the conventional particle reinforced composites, the fracture strain increased with the nano ?-Cristobalite addition, an effect which was ascribed to the intrinsic NPR behavior of the filler. © 2023 Elsevier B.V.Article Citation - WoS: 8Citation - Scopus: 9Dynamic Computational Wear Model of Peek-On Bearing Couple in Total Hip Replacements(Elsevier, 2023) Alpkaya, Alican Tuncay; Mihçin, ŞenayUnderstanding wear mechanisms is a key factor to prevent primary failures causing revision surgery in total hip replacement (THR) applications. This study introduces a wear prediction model of (Polyetheretherketone) PEEK-on-XLPE (cross-linked polyethylene) bearing couple utilized to investigate the wear mechanism under 3D-gait cycle loading over 5 million cycles (Mc). A 32-mm PEEK femoral head and 4-mm thick XLPE bearing liner with a 3-mm PEEK shell are modeled in a 3D explicit finite element modeling (FEM) program. The volumetric and linear wear rates of XLPE liner per every million cycles were predicted as 1.965 mm3/Mc, and 0.0032 mm/Mc respectively. These results are consistent with the literature. PEEK-on-XLPE bearing couple exhibits a promising wear performance used in THR application. The wear pattern evolution of the model is similar to that of conventional polyethylene liners. Therefore, PEEK could be proposed as an alternative material to the CoCr head, especially used in XLPE-bearing couples. The wear prediction model could be utilized to improve the design parameters with the aim of prolonging the life span of hip implants. © 2023Article Citation - WoS: 36Citation - Scopus: 37Numerical Investigation of Melting Process for Phase Change Material (pcm) Embedded in Metal Foam Structures With Kelvin Cells at Pore Scale Level(Elsevier, 2023) Sabet, Safa; Buonomo, Bernardo; Sheremet, Mikhail A.; Manca, OronzioThe present numerical study analyzes the melting process of phase change material (PCM) embedded in a metallic foam structure at pore scale level. The computational domain consists of two different sizes of 3D cubic boxes. The analyzed domain is filled with Kelvin cell-structures with different Cell Per Length (CPL) and constant porosity of 0.956. A constant temperature, higher than the melting temperature of PCM, is assigned to one external surface of the enclosure, while the other surfaces are adiabatic. The conjugate problem for the heat transfer between the PCM and the solid structure with Kelvin cells is developed. Enthalpy-porosity method is used to describe the PCM melting process. The finite volume method is used to solve the conjugate heat transfer problem at pore scale level by Ansys-Fluent code. A comparison of different CPL values is reported in terms of liquid fraction, average temperature of the PCM, and energy storage. The comparison is also considered between the two different volumes of the cubic boxes. The presence of the metallic structured Kelvin cells increases the overall heat transfer rate and decreases the melting time. Results for smaller cavity indicates that as the CPL number increases, the time required for the PCM melting process decreases. Furthermore, the total heat accumulation process takes a shorter time to reach the maximum value. The melting time and the duration of heat accumulation are worsened for the large cubic box (L = 4 inch) at CLP>6. This is due to the dominant viscous effect, which decreases the velocity induced by the buoyancy forces because of higher contact surface area. In these cases, heat transfer between liquid and solid phases of the PCM decreases substantially. © 2023 Elsevier LtdArticle Citation - WoS: 18Citation - Scopus: 19The Impact Response of a Nomex® Honeycomb Core/E-glass Composite Sandwich Structure To Increasing Velocities: Experimental and Numerical Analysis(Elsevier, 2023) Çelik, Muhammet; Güden, Mustafa; Sarıkaya, Mustafa; Taşdemirci, Alper; Genç, Cem; Ersoy, Kurtuluş; Serin, ÖzgürThe impact response of an E-glass fiber reinforced epoxy/Nomex® honeycomb core sandwich was investigated both experimentally and numerically at increasing velocities through concentrated quasi-static indentation force (CQIF), low velocity impact (LVI) and high velocity impact (HVI) tests. The composite face sheets and core were modelled using MAT_162 and MAT_026 homogenized material model in LS-DYNA, respectively. The experimental and numerical LVI test forces corresponding to core crushing and face sheet penetration were shown to be higher than those of the CQIF tests and increased as the impactor velocity increased. The increase of the impact forces at increasing velocities was largely ascribed to the inertia and the strain rate sensitive fracture strength of the composite sheets. The core shearing was detected in the CQIF and LVI tests both experimentally and numerically. It was also detected in the HVI tests at the velocities less than 20 m s?1. The deformation in the HVI tests at and above ? 29.4 m s?1 was highly localized in the impact area with no core shearing and a large delamination damage area at the front face sheet. The force enhancement due to the micro-inertia of the core deformation was shown to be not significant at the studied velocities. © 2023 Elsevier LtdReview Citation - WoS: 103Citation - Scopus: 136Digital Twin of Electric Vehicle Battery Systems: Comprehensive Review of the Use Cases, Requirements, and Platforms(Elsevier, 2023) Naseri, Farshid; Gil, S.; Barbu, C.; Jensen, A. C.; Larsen, P. G.; Gomes, Claudio; Çetkin, Erdal; Yarımca, GülşahTransportation electrification has been fueled by recent advancements in the technology and manufacturing of battery systems, but the industry yet is facing serious challenges that could be addressed using cutting-edge digital technologies. One such novel technology is based on the digital twining of battery systems. Digital twins (DTs) of batteries utilize advanced multi-layer models, artificial intelligence, advanced sensing units, Internet-of-Things technologies, and cloud computing techniques to provide a virtual live representation of the real battery system (the physical twin) to improve the performance, safety, and cost-effectiveness. Furthermore, they orchestrate the operation of the entire battery value chain offering great advantages, such as improving the economy of manufacturing, re-purposing, and recycling processes. In this context, various studies have been carried out discussing the DT applications and use cases from cloud-enabled battery management systems to the digitalization of battery testing. This work provides a comprehensive review of different possible use cases, key enabling technologies, and requirements for battery DTs. The review inclusively discusses the use cases, development/integration platforms, as well as hardware and software requirements for implementation of the battery DTs, including electrical topics related to the modeling and algorithmic approaches, software architec-tures, and digital platforms for DT development and integration. The existing challenges are identified and circumstances that will create enough value to justify these challenges, such as the added costs, are discussed.Article Citation - WoS: 12Citation - Scopus: 17Development of the Johnson-Cook Flow Stress and Damage Parameters for the Impact Response of Polycarbonate: Experimental and Numerical Approach(Elsevier, 2023) Sarıkaya, Mustafa; Güden, Mustafa; Kambur, Çağdaş; Çankaya Özbek, Sevim; Taşdemirci, AlperThe Johnson and Cook (JC) flow stress and damage model parameters of a polycarbonate (PC) plate were determined by the mechanical tests and numerical simulations of the tests. The experimental tests included quasi-static and high strain rate tension and compression, quasi-static notched-specimen tension, quasi-static indentation (QSI), low velocity impact (LVI) and projectile impact (PI). Initially, five different quasi-static flow stress-strain equations were extracted from the experimental and numerical tests. The flow stress equa-tion determined from the experimental average true stress-true strain curve well agreed with the effective stress -strain obtained from the quasi-static numerical tension test. The numerical QSI force-displacement curve based on the experimental average true stress-true strain equation was further shown to be very similar to that of the experiment. The LVI and PI test simulations were then continued with the experimental average true stress-true strain equation using five different flow stress-strain rate relations: JC, Huh and Kang (HK), Allen-Rule and Jones (ARJ), Cowper-Symonds (CS) and the nonlinear rate approach (NLA). The rate sensitivity parameters of these relations were extracted from the quasi-static and high strain rate tests. The LVI test simulations using the stress -strain rate relations exhibited force-displacement curves higher than those of the experiments. The detected almost no strain rate sensitivity in the LVI tests was ascribed to low strain rate dependency of the flow stress at these intermediate strain rates and large strains involved. On the other side, all the stress-strain rate relations investigated nearly predicted the experimental damage types: dishing at 100 and 140 m s-1 and petalling at 160 m s- 1, except the CS relation which predicted the fracture of the plate at 140 m s-1. The experimental average projectile exit velocity at 160 m s- 1 was further well predicted by the used stress-strain rate relations while the experimental average petal thicknesses were under estimated by the models. The absorbed energy at 160 m s-1 PI test was determined 1.6 times that of the QSI test, which proved an increased energy absorption capability of the tested PC at the investigated impact velocities.