Mechanical Engineering / Makina Mühendisliği
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Article Enhancing trajectory-tracking accuracy of high-acceleration parallel robots by predicting compliant displacements(Cambridge University Press, 2025) Paksoy, Erkan; Dede, Mehmet Ismet Can; Kiper, GokhanFor precision-required robot operations, the robot's positioning accuracy, repeatability, and stiffness characteristics should be considered. If the mechanism has the desired repeatability performance, a kinematic calibration process can enhance the positioning accuracy. However, for robot operations where high accelerations are needed, the compliance characteristics of the mechanism affect the trajectory-tracking accuracy adversely. In this paper, a novel approach is proposed to enhance the trajectory-tracking accuracy of a robot operating at high accelerations by predicting the compliant displacements when there is no physical contact of the robot with its environment. Also, this case study compares the trajectory-tracking characteristics of an over-constrained and a normal-constrained 2degrees-of-freedom (DoF) planar parallel mechanism during high-acceleration operations up to 5 g accelerations. In addition, the influence of the end-effector's center of mass (CoM) position along the normal of the plane is investigated in terms of its effects on the proposed trajectory-enhancing algorithm.Article Citation - WoS: 1Citation - Scopus: 1Analysis and Comparison of the Projectile Impact Response of an Electron Beam Melt-Ti64 Body Centered Cubic Lattice-Cored Sandwich Plate(Springer, 2025) Erten, H.İ.; Çimen, G.; Yıldıztekin, F.M.; Güden, M.Background: One potential application of additively fabricated lattice structures is in the blade containment rings of gas turbine engines. The blade containment rings are expected to be able to absorb the kinetic energy of a released blade (broken blade) in order to protect the engine parts from damaging. Metallic lattice-cored sandwich plates provide a gap (free space) between two face sheets, which helps to arrest the released blade and increases the energy absorption capability of containment rings. Objective: The objective was to investigate numerically the projectile impact response of Body-Centered-Cubic (BCC) Electron-Beam-Melt (EBM) lattice-cored/Ti64 face sheet sandwich plates as compared with that of an equal-mass monolithic EBM-Ti64 plate. Methods: The projectile impact simulations were implemented in LS-DYNA using the previously determined flow stress and damage models and a spherical steel impactor at the velocities ranging from 150 to 500 m s−1. The experimental projectile impact tests on the monolithic plate were performed at two different impact velocities and the results were used to confirm the validity of the used flow stress and damage models for the monolithic plate models. Results: Lower impact stresses were found numerically in the sandwich plate as compared with the monolithic plate at the same impact velocity. The bending and multi-cracking of the struts over a wide area in the sandwich plate increased the energy absorption and resulted in the arrest of the projectile at relatively high velocities. While monolithic plate exhibited a local bent area, resulting in the development of high tensile stresses and the projectile perforations at lower velocities. Conclusions: The numerical impact stresses in the sandwich plate were distributed over a wider area around the projectile, leading to the fracture and bending of many individual struts which significantly increased the resistance to the perforation. Hence, the investigated lattice cell topology and cell, strut, and face sheet sizes and the lattice-cored sandwich plate was shown potentially more successful in stopping the projectiles than the equal-mass monolithic plates. © The Author(s) 2025.Article Ağır Ticari Araçlarda Kullanılan Bir Volanın Parametrik Optimizasyon Yöntemiyle Tasarımının İyileştirilmesi(2022) Sırmalılar, Mehmet Yalçın; Haktanır, Murat; Saklakoğlu, Nurşen; Eş, CanerOtomotiv endüstrisinde rekabetçi olabilmenin anahtarı ürün geliştirmenin ilk aşamalarında üretim maliyetini ve ürün performansını düşünerek daha iyi yapısal tasarımlar elde etmektir. Son yıllarda sonlu eleman analizindeki gelişmeler daha güvenli ve daha ucuz tasarımların oluşturulmasını sağlamış ve bu yeteneği kazanan firmalar önemli avantajlar elde etmiştir. Bu çalışmada Dönmez Debriyaj firmasında seri üretimi yapılan bir volanın malzeme maliyetini azaltmak üzere boyut optimizasyonu gerçekleştirilmiştir. Bilgisayar destekli sonlu elemanlar yöntemi ile volanın çalışma koşulları simüle edilmiş, parametrik optimizasyon yöntemi ile volan için istenen mekanik özellikleri sağlamanın yanı sıra maliyeti en düşük tutacak şekilde optimizasyon yapılmıştır. Bu çalışma sonunda volan ağırlığı 27,956 kg’dan 26,019 kg’a düşürülerek, toplam volan ağırlığından %6,93 azaltma sağlanmıştır ve ilgili volan, analizlerden elde edilen sonuçlar doğrultusunda talaşlı üretim ile revize edilerek üretilmiş ve araç testine tabi tutulmuştur. Bu test sonucunda hiçbir hasarla karşılaşılmamıştır.Article Citation - WoS: 2Citation - Scopus: 3Design and Manufacturing of a Hip Joint Motion Simulator With a Novel Modular Design Approach(Springer, 2024) Torabnia, S.; Mihçin, D.Ş.; Lazoglu, I.The study is aimed to develop a hip joint wear simulator using a modular design approach to help experimentally monitor and control critical wear parameters to validate in-silico wear models. The proper control and application of wear parameters such as the range of motion, and the applied force values while estimating the lost material due to wear are essential for thorough analysis of wear phenomena for artificial joints. The simulator's dynamics were first modeled, then dynamic loading data was used to calculate the forces, which were further used for topology optimization to reduce the forces acting on each joint. The reduction of the link weights, connected to the actuators, intends to improve the quality of motion transferred to the femoral head. The modular design approach enables topology-optimized geometry, associated gravitational and dynamic forces, resulting in a cost-effective, energy-efficient product. Moreover, this design allows integration of the subject specific data by allowing different boundary conditions following the requirements of industry 5.0. Overall, the in-vitro motion stimulations of the hip-joint prosthesis and the modular design approach used in the study might help improve the accuracy and the effectiveness of wear simulations, which could lead into the development of better and longer-lasting joint prostheses for all. The subject-specific and society-based daily life data implemented as boundary conditions enable inclusion of the personalized effects. Next, with the results of the simulator, CEN Workshop Agreement (CWA) application is intended to cover the personalized effects for previously excluded populations, providing solution to inclusive design for all. © 2023, The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature.Article Citation - WoS: 9Citation - Scopus: 11Experimental Investigation of Spray Characteristics of Ethyl Esters in a Constant Volume Chamber(Springer, 2024) Ulu, A.; Yildiz, G.; Özkol, Ü.; Rodriguez, A.D.Abstract: Biodiesels are mainly produced via the utilization of methanol in transesterification, which is the widespread biodiesel production process. The majority of this methanol is currently obtained from fossil resources, i.e. coal and natural gas. However, in contrast with methanol, biomass-based ethanol can also be used to produce biodiesels; this could allow the production line to become fully renewable. This study aimed to investigate the spray characteristics of various ethyl ester type biodiesels derived from sunflower and corn oils in comparison to methyl esters based on the same feedstocks and reference petroleum-based diesel. Spray penetration length (SPL) and spray cone angle (SCA) were experimentally evaluated in a constant volume chamber allowing optical access, under chamber pressures of 0, 5, 10 and 15 bar and injection pressures of 600 and 800 bar. Sauter mean diameter (SMD) values were estimated by using an analytical correlation. Consequently, ethyl esters performed longer SPL (2.8–20%) and narrower SCA (5.1–19%) than diesel under ambient pressures of 5 and 10 bar. Although the SMD values of ethyl esters were 48% higher than diesel on average, their macroscopic spray characteristics were very similar to those of diesel under 15 bar chamber pressure. Moreover, ethyl esters were found to be very similar to methyl esters in terms of spray characteristics. The differences in SPL, SCA and SMD values for both types of biodiesels were lower than 4%. When considering the uncertainty (± 0.84%) and repeatability (±5%) ratios, the difference between the spray characteristics of methyl and ethyl esters was not major. Graphical abstract: [Figure not available: see fulltext.] © 2022, The Author(s), under exclusive licence to Springer-Verlag GmbH Germany, part of Springer Nature.Article Citation - WoS: 5Citation - Scopus: 5A Continuously Variable Transmission-Based Variable Stiffness Actuator for Phri: Design Optimization and Performance Verification(American Society of Mechanical Engineers, 2024) Mobedi, Emir; Dede, Mehmet İsmet CanPhysical human–robot interfaces (pHRIs) enabled the robots to work alongside the human workers complying with the regulations set for physical human–robot interaction systems. A variety of actuation systems named variable stiffness/impedance actuators (VSAs) are configured to be used in these systems’ design. Recently, we introduced a new continuously variable transmission (CVT) mechanism as an alternative solution in configuring VSAs for pHRI. The optimization of this CVT has significant importance to enhance its application area and to detect the limitations of the system. Thus, in this paper, we present a design optimization approach (an adjustment strategy) for this system based on the design goals, desired force, and minimization of the size of the system. To implement such design goals, the static force analysis of the CVT is performed and validated. Furthermore, the fabrication of the optimized prototype is presented, and the experimental verification is performed considering the requirements of VSAs: independent position and stiffness variation, and shock absorbing. Finally, the system is calibrated to display 6 N continuous output force throughout its transmission variation range. © 2024 by ASME.Article Citation - WoS: 9Citation - Scopus: 10The Design and Kinematic Representation of a Soft Robot in a Simulation Environment(Cambridge Univ Press, 2024) Emet, Hazal; Gur, Berke; Dede, Mehmet Ismet CanThe increase of human presence in the subsea and seabed environments necessitates the development of more capable and highly dexterous, innovative underwater manipulators. Biomimetic soft-robot arms represent a promising candidate for such manipulation systems. However, the well-known modeling techniques and control theories of traditional rigid robots do not apply to soft robots. The challenges of kinematic and dynamic modeling of soft robots with infinite degrees of freedom require the development of dedicated modeling methods. A novel procedure for representing soft-robotic arms and their motion in a rigid-body simulation environment is proposed in this paper. The proposed procedure relies on the piecewise constant curvature approach to simplify the very complex model of hyper-redundant soft-robotic arms, making it suitable for real-time applications. The proposed method is implemented and verified to be used in model-mediated teleoperation of the soft arms of a biomimetic robotic squid designed for underwater manipulation as a case study.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: 2Citation - Scopus: 3Design and Manufacturing of a Hip Joint Motion Simulator With a Novel Modular Design Approach(Springer, 2023) Torabnia, Shams; Mihçin, Şenay; Lazoğlu, İsmailThe study is aimed to develop a hip joint wear simulator using a modular design approach to help experimentally monitor and control critical wear parameters to validate in-silico wear models. The proper control and application of wear parameters such as the range of motion, and the applied force values while estimating the lost material due to wear are essential for thorough analysis of wear phenomena for artificial joints. The simulator's dynamics were first modeled, then dynamic loading data was used to calculate the forces, which were further used for topology optimization to reduce the forces acting on each joint. The reduction of the link weights, connected to the actuators, intends to improve the quality of motion transferred to the femoral head. The modular design approach enables topology-optimized geometry, associated gravitational and dynamic forces, resulting in a cost-effective, energy-efficient product. Moreover, this design allows integration of the subject specific data by allowing different boundary conditions following the requirements of industry 5.0. Overall, the in-vitro motion stimulations of the hip-joint prosthesis and the modular design approach used in the study might help improve the accuracy and the effectiveness of wear simulations, which could lead into the development of better and longer-lasting joint prostheses for all. The subject-specific and society-based daily life data implemented as boundary conditions enable inclusion of the personalized effects. Next, with the results of the simulator, CEN Workshop Agreement (CWA) application is intended to cover the personalized effects for previously excluded populations, providing solution to inclusive design for all.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.