Abstract

Projeksiyon kaynak yöntemi otomotiv endüstrisinde en yaygın kullanılan üretim metotlarından biridir. Yapılan çalışmada otomotiv yan sanayisi tarafından üretilen sac metal parçaların projeksiyon kaynak prosesi incelenmiştir. Çalışma kapsamında yetersiz kaynak mukavemeti sorunu ele alınmıştır. 0.5 mm kalınlığındaki detay braket parçası üzerine uygulanan kaynak mukavemetinin yeterli olmadığı sonucuna ulaşılmıştır. Bu nedenle parça geometrisi yeniden tasarlanarak sac kalınlığı 1 mm’ye ve kaynak kabartma sayısı 4’e çıkartılmıştır. Kaynak kalitesinin arttırılması amacıyla ise geleneksel bakır elektrot yerine U geometrili yeni bir elektrot tasarlanmıştır. Yeniden tasarlanan parça geometrisi ve elektrot geometrilerinin kaynak mukavemeti üzerindeki etkisini görmek, kaynak akımı ve baskı kuvveti gibi kaynak parametrelerinin proses özelinde çalışma parametrelerini analiz etmek için Taguchi L9 deney tasarımı kullanılmıştır. Kaynak zamanı sabit tutulan çalışmada analiz sonuçları keski-çekiç testleri, optik mikroskop ve SEM analizleri ile değerlendirilmiş, en uygun kaynak parameter değerleri belirlenmiştir. Yapılan iyileştirmeler ile kaynak süresi azalırken, proses verimliliği artmıştır.

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