Akademik Veri Yönetim Sistemi
Gumushane Universitesi Fen Bilimleri Dergisi, cilt.15, sa.3, ss.728-739, 2025 (Scopus, TRDizin)
Increasing tool life and thus reducing maintenance costs in hole punching of ultra-high strength sheet metal is critical for the automotive industry. In this study, the punch raw material (Vanadis 4E and Caldie ESR), punch coating (uncoated, AlCrN, TiAlCN), punch tip radius (0.1, 0.3 and 0.5 mm) and clearance (15%, 22% and 30% of the sheet thickness) parameters affecting the punch life were statistically optimised by Taguchi method and ANOVA analyses for maximum punch life and maintenance cost calculation. Taguchi method results showed that Caldie ESR should be selected as the raw material, TiAlCN as the coating type, 0.3 mm as the tip rounding radius and 15% of the sheet as the cutting gap for the highest punch life. As a result of ANOVA analyses, coating type with a contribution rate of 61.71% and then cutting gap with a contribution rate of 24.12% were determined as the most effective factors. Thanks to the statistical optimisation, the punch life has been increased from 2538 to 22080 operations, while a gain of approximately 465819 TL in maintenance costs for 100000 punching operations has been achieved. The necessity of statistical process optimisation for punch life improvement and indirectly minimising maintenance costs in hole punching of ultra-high strength sheets has been successfully demonstrated.