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The Cathodic Electrolytic Plasma Hardening of Steel and Cast Iron Based Automotive Camshafts

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Dayanç A., Karaca B., Kumruoğlu L.
Acta Physica Polonica A
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2017
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vol. 131
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issue 3
374-378
EN
Cathodic electrolytic plasma hardening is a novel thermochemical surface modification and hardening process, used to increase wear resistance and surface hardness of metallic components in a local area of interest. The heating efficiency is related with the plasma nozzle design, applied current and electrolyte. The nozzle design is also a critical factor for the hardening of complex shapes, such as gears and camshafts. In this work, lobes of camshafts, fabricated from several cast iron and steel grades were hardened by cathodic electrolytic plasma hardening in aqueous carbonate electrolyte, using a specific plasma nozzle. The camshafts were attached to CNC lathe for turning them in the horizontal axis. In order to optimise heating and to achieve the ideal flowing and wetting by the electrolyte of the lobe case, the ceramic ellipse-shaped nozzle outlet was designed. As a result of preliminary studies, external surface of lobes was heated and subsequently quenched by electrolyte. The hardness of processed surface was in the range of 50-60 HRc for the different camshafts. No distortion was observed on the surface of lobes. Hardness depth was measured to be from 0.1 mm to 5 mm for several lobes.
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A Simulation and Fabrication Works on Optimization of High Pressure Aluminum Die Casting Part

100%
Ertürk S., Kumruoğlu L., Özel A.
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vol. 125
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issue 2
449-451
EN
High-pressure die casting offers reduced costs due to its small tolerances and smooth surface finish. Casting parts produced are consumed by the automotive industry in millions. In this study, the use of computer aided engineering applications on design of high-pressure die-casting was studied. The influence of casting process steps in die design was studied and analyzed. The casting simulation software was used to improve design and solve problems. By using the simulation software in analyses of die design, the final design was reached in a few hours and thus the design process of pre-production was shortened and mold production was carried out with no revision on die material. Radiographic test was applied on the casting parts and the result shows good correlation between simulations of solidification result data. Also the results proved that the application of squeeze pressure in the intensification phase of high-pressure die casting process could be examined in the casting simulation.
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