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Öğe A New Hybrid Method, Density-Shape-Element Removal (D-S-ER), for the Optimization of Continuum Structures(Pleiades Publishing Inc, 2023) Teke, Ibrahim T.; Yilmaz, Yasin; Baykara, Celalettin; Ertas, Ahmet H.Mesoscale lattice structures can be used in the design of lightweight structures using additive manufacturing without significantly raising production costs. However, creating effective structures with intricate latticework is difficult. Therefore, this paper presents a new strategy for designing additively manufactured structures that can simultaneously optimize the continuum structures. A novel hybrid algorithm has been created by combining the density-based approach, shape optimization, and element removal method (D-S-ER) to achieve the desired purposes of higher strength and/or lightweight structures. Three distinct issues-the cantilever beam, the corbel structure, and the GE bracket-that were addressed by many scientists were taken into account and resolved using the method that has been developed. As seen from the tables presenting the results obtained, significant improvements in terms of strength as well as the weight of the structures can be obtained. Hence, the results of the study demonstrate the effectiveness of the proposed procedure.Öğe A Predictive Model for Fatigue Performance in Spot Welded and Bolted Joints(Springer, 2025) Teke, Ibrahim T.; Baykara, Celalettin; Akbulut, Mustafa; Ertas, Ahmet H.This study examines the fatigue behavior of spot-welded and bolted single-lap joints through an integrated framework combining experimental testing, finite element analysis (FEA), and regression modeling. The investigation focuses on how geometric parameters-such as plate width, length, thickness, and overlap length-affect fatigue life under variable loading conditions. Fatigue tests serve as the foundation for developing a predictive model for low-cycle fatigue, while FEA provides detailed insights into stress concentrations at critical regions like weld nuggets and bolt holes. Results show that bolted joints, particularly those using M4 fasteners, exhibit superior fatigue performance due to more uniform stress distribution and reduced localization. Submodel-based FEA confirms these findings, revealing that bolted configurations better disperse stresses compared to the high gradients observed near spot welds. This combined approach enhances fatigue life prediction accuracy and offers practical guidance for optimizing joint geometry in automotive, aerospace, and mechanical engineering applications.Öğe Carrier skid design for multi-model vehicle bodies: experimental and numerical insights(Emerald Group Publishing Ltd, 2025) Baykara, Celalettin; Teke, Ibrahim T.; Ertas, Ahmet H.PurposeThis study aims to redesign and optimize production skids in an automobile factory's paint shop to enhance productivity and efficiency within a lean manufacturing framework. By accommodating all vehicle types on a single skid design, the research seeks to minimize production time, reduce costs and improve operational reliability through total productive maintenance (TPM). The solution is robust in terms of its scalability to multiple vehicle models, significant cost savings and marked improvements in operational performance. The study also explores the effects of skid design and pallet rigidity on manufacturing line performance, providing a robust solution to streamline the production process while addressing key challenges in automotive manufacturing.Design/methodology/approachThe study uses a comprehensive methodology, combining numerical analysis (finite element analysis, [FEA]) and experimental validation, to redesign production skids for accommodating multiple vehicle types. Annual production data was analyzed to identify commonalities among car bodies for skid optimization. Lean principles - particularly Kaizen and TPM - uniquely influenced the redesign by emphasizing waste elimination, continuous improvement and equipment reliability. After conceptual design, FEA was used to evaluate skid rigidity under gravity loads for different pallet configurations (flexible vs. rigid). Virtual positioning of car models on design-verified skids preceded the fabrication and implementation of skids on the production line. Maintenance strategies included replacing worn-out components to ensure seamless operations. Numerical validation assessed the impact of pallet rigidity on skid deformations, enhancing the reliability of the proposed designs in a real-world manufacturing environment.FindingsThe optimized skid design successfully accommodated all vehicle types, reducing the number of skids, production time and costs. Efficiency gains included a 44% reduction in downtime and a 47% decrease in production line stops. Numerical analysis confirmed the significance of pallet rigidity in minimizing skid deformations, validating the redesign approach. In addition, eliminating a low-production car model further streamlined the process. A cost-benefit discussion showed that phasing out this model freed up skid capacity and reduced operational complexity, resulting in net savings. The integration of lean manufacturing principles and TPM demonstrated significant improvements in operational efficiency, offering a scalable framework for enhancing productivity in automotive manufacturing.Originality/valueThis study presents a novel approach to optimizing production skids for lean automotive manufacturing. By integrating numerical analysis, experimental validation and maintenance strategies, the research offers an innovative solution to common industry challenges, such as accommodating diverse vehicle types and reducing operational inefficiencies. Unlike previous studies that focus on single-vehicle fixtures, this work addresses a multimodel skid solution under a TPM-maintained environment. The findings emphasize the importance of considering pallet rigidity in skid design and demonstrate the practical benefits of eliminating low-production models. These insights provide valuable guidance for manufacturers seeking to enhance production line reliability, reduce costs and maintain a competitive edge in the automotive industry.Öğe Effects of the single-lap joint on fatigue strength of metals with different surface coatings: a numerical simulation(EDP Sciences, 2023) Baykara, Celalettin; Teke, Ibrahim T.; Ertas, Ahmet H.Due to their low cost and ease of use, adhesives are frequently used in the industry. Selecting adherents and adhesives is essential when thinking about a construction that uses them. A fatigue study is therefore required to determine the best adherents and adhesives. In this situation, a prediction model must be incorporated into the process. In this study, Single-lap joint (SLJ) was chosen. Specimens with uncoated, primed, and cataphoresis-treated surfaces on DC01 steel sheet surfaces have been taken into account. A numerical solution was produced to obtain the fatigue life of the structures. Results indicate that the produced approach can provide an accurate estimate of fatigue resistance of different bonding methods including adhesive joints with various coating and adhesive thicknesses combined with adhesive techniques. © The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0 (https://creativecommons.org/licenses/by/4.0/).Öğe Microstructure and Surface Roughness Connection on Machined Ductile Iron: An Experimental Determination(EDP Sciences, 2024) Teke, Ibrahim T.; Oktay, Mehmet; Baykara, Celalettin; Ertas, Ahmet H.Ductile iron is useful for a variety of engineering challenges because of its ductility and high strength. Hence, it is an excellent option if machining is required. After milling operations, however, various surface characteristics could be created, and surface roughness could be assessed. On the other hand, machined surface roughness is constrained by production requirements. As a result, the association between surface roughness and machining parameters has been studied in the literature. Studies that focus on the relationship between surface roughness and microstructure in the context of material qualities are also available. In this study, an experimental investigation of a part made of EN-GJS-600-3 material took into account the significance of the interaction between microstructure and surface roughness. In addition to machining parameters, surface roughness, hardness (Brinell Hardness), and microstructure of machined surfaces are taken into consideration. The findings show that surfaces with pearlitic compositions are highly abrasive. Hardness rose along with an increase in the pearlitic phase. The number of spheres and surface roughness follow the same trend. © The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0 (https://creativecommons.org/licenses/by/4.0/).
