MECHANICAL ENGINEERING MS THESIS DEFENSE BY DENİZHAN KORKUT



Title: Investigation of a Topology Optimized Boring Bar Design with Graded Lattice Infill

Speaker: Denizhan Korkut

Time: January 06, 2023; 15:30

Place: Zoom

Thesis Committee Members:

Prof. İsmail Lazoğlu (Advisor, Koç University)

Prof. Murat Sözer (Koç University)

Assist. Prof Lütfi Taner Tunç (Sabancı University)

Abstract:

Chatter free cutting had always been a target for manufacturers and machine component providers as the phenomena causes the tool wear, wavy surfaces on machined surface and shorten the tool life. In order to deal with the problem, spindle speed and depth of cut should be selected with caution. This thesis introduces a technique that consists of the formation of lattice structures inside the boring bar with the use of additive manufacturing to be used in boring process in order to increase the limiting depth of cut and improve the efficiency. Following this work, a novel hybrid boring bar with superior dynamic characteristics was designed by utilizing Topology Optimization (TO) and graded lattice structures. Fused Deposition Modeling technique was selected as the manufacturing process for the structure. Frequency Response Functions were generated to determine the dynamic characteristics of the optimized boring bar and validate the analysis experimentally. The newly designed boring bar is optimized to provide a larger selection of parameters in boring operations and increase productivity. The main objective of this research is to explore the potential advantages that topology optimization and lattice structures can bring in the context of boring operation efficiency.