Computer aided investigation of the effect of mechanical properties on metal forming production parameters

In this study, hot forging and press hot forming processes were designed in the context of theoretical, industrial and literature supported studies carried out in order to investigate the effect of mechanical properties of hot forging and press hot forming methods on the mold, aimed to investigate the effect of manufacturing parameters which are effective on forming methods on mechanical properties was targeted. Within the scope of the thesis study, especially wooden supports which are one of the main causes of mining accidents in Turkey in recent years, the production of ground supports connection clamps, which is an important components of the TH34 mining ground supports used by importing in our country, has been taken into consideration. In the scope of design works, forging and bending molds which are used in the production of clamps and upper and lower connection clamps according to TH34 profile and standard which are produced according to DIN21530 standard are designed. Within the context of simulation activities such as press selection, raw material preparation stages, mold selection and design, final product geometry and simulation of the whole process, material flow, residual stress-strain distribution, temperature effect and friction coefficient were evaluated in detail and contributed to improvement of final product mechanical properties. The optimum production parameters are determined. TH34 lower and upper support clamps' pilot production was carried out using optimum production parameters determined by molds designed in line with standards and simulation studies based on Finite Elements and Finite Volume Methods. As a result; New product design and development, production method revision-cost reduction, final product characterization steps have been carried out with scientific-based R & D studies by combining modeling simulation applications with hot forging and press hot forming methods in the production of mining support clamps. The prototype product obtained as a result of technical-theoretical and literature supported work has emerged as a new generation support connection clamps with improved mechanical performance and metallurgical properties, improved operational performance and safety.