UNIVERSITY OF GAZIANTEP

MECHANICAL ENGINEERING DEPARTMENT

ME299
SUMMER PRACTICE PROGRAM REPORT
Summer 2007
Kazan/ANKARA

Prepared by:
Erhan STBA
2427097

CONTENTS
1.

INTRODUCTION........................................................................................................4

2.

DESCRIPTION OF THE COMPANY.........................................................................5

2.1)

Location of the Company........................................................................ 5

2.2)

History of the Company...............................................................................6

2.3)

Main Area about the Company....................................................................6

2.4)

Number of Staff and Distribution of Engineers.............................................6

2.5)

Functions of Mechanical Engineers in the Company...................................7

2.6)

Vision & Mission of UNTES......................................................................7

2.7)

Organizational Structure of the Company.....8

3) MANUFACTURING STEPS .........................................................................................8

3.1) Inputs of the Factory.....................................8
3.2) Processes & Machines..................................................................8
3.3) Production Flow...11
4) PRODUCTION TECHNIQUES USED IN THE ORGANIZATION......12
4.1) Material Removal Processes ........................................ 12
4.1.1) Cutting.......13
4.1.1.1) Plasma Arc Cutting..............................................13
4.1.1.2. a) CNC Oxy-Fuel Gas Cutting.................................15
b) Optical Oxy-Fuel Gas Cutting...........................................15
4.1.1.3) Shearing................................................................................15
4.1.1.4) Sawing.............................................................16
4.1.2) Milling...............17
4.1.3) Turning.........20
4.1.4) Drilling...23
4.1.5) Boring.......26
4.1.6) Grinding........28
4.1.7) Piercing and Blanking........32
4.2) Forming Operations ......33
4.2.1) Bending........33

4.2.1.1) Angle Bending..............34

4.3) Joining Processes.........................35
4.3.1) Welding.........35
4.3.1.1) Oxyfuel Gas Welding.............................35
4.3.1.2) Arc Welding..................36
4.3.1.2.1) Shielded Metal Arc Welding (SMAW)..........36
4.3.1.2.2) Gas Tungsten Arc Welding (GTAW).......................36
4.3.1.2.3) Gas Metal Arc Welding (GMAW)...................................37
4.4) Surface Treatment and Finishing Processes..............38
4.4.1) Sand Blasting...38
4.4.2) Heat Treatment....39
4.4.2.1) Annealing Process ..................40
5) COMPUTER NUMERICAL CONTROL......40
6) OPERATION SEQUENCES OF SOME PARTS......41
6.1) Flag......... ..........................................................41
6.2)I-beam.....................................................41
6.3) Welded platform...........................................................................................41
6.4)Joint part........................................................................................................42
6.5) Combined I beam platform.......42
7) COST ANALYSIS OF ONE CHOSEN PART....43
7.1) Fan-Coil.............................43
8) CONCLUSION.............................44

APPENDIX A: CHART
1

UNTES Organization

1. INTRODUCTION
In mechanical engineering the manufacturing technologies have an important role. In
order to improve the manufacturing technology knowledge, the junior year students must attend a
summer practice program for mechanical engineering.

In the summer practice program the students put their theoretical values learned in previous
courses into practice by the help of engineers and technicians who are responsible from the
processes in the organization. Especially for the production techniques the summer practice
program is much more useful. In this program the student can inspect the processes like milling,
drilling, turning, grinding, etc. and learn some of the details about the working principles of the
machines, which are used in the company. Also the student gets some information about the
speed, mechanism, capacity and the fields of use of these machines. There is one to one
correspondence between these increments band also the working principles of the machines.
During the summer practice the students can easily get answers to their problems and questions
about the details of the processes

2. DESCRIPTION OF THE COMPANY

2.1.Location of the Company

COMPANY

LOCATION

TEL.

FAX

UNTES Heating Ventilating and Air

Conditioning A.S.

Istanbul high-way 37rd km. Kazan

ANKARA/TURKEY

(0312)814-1216

(0312)814-1226

2.2.History of the Company

UNTES esteblished in 1968, UNTES has become a leading developer and manufacturer in a wide
range of heating, cooling, air conditioning and ventilating equipment since then and has been
appreciated amongs the pioneers of ndustry and approved by both of private and public sector.
Being aware of that key factors of success and continuity would be unconditional costumer
safisfaction and investment
people, today, UNTES Heating Ventilating and Air Conditioning A.S. keeps on growing with its
professsional team consist of young, dynamic engineers and experienced professionals as well as
management organisation leading new ideas to this team. Having its head office and producing
plants in Ankara being located in Ankara, UNTES has also branch offices in stanbul, zmir and
Adana.
They all have been manufactured in our factories covering 40.000 m2 open area and 10.500 m2
closed area located on Ankara-stanbul old motorway 37 th km.
2.3.Main sphere of companiy
UNTES is now working on the,
Standard Air Handling Units,
Hygienic Air Handling Units,
Surgical Room Air Conditioners,
Ceiling Type Air Handling Units,
Roof-Top Air Conditioners,
Fresh Air Units,
Roof Type Exhaust Aspirators,
Cooling Towers with Radial Fans,
Wall Mounted Unit Heaters with Radial Fans,
Wall Mounted Unit Heaters with Axial Fans,
Fancoil Units,
Laminar Air Flow Ceilin
When I participate in production, the factory operates all of them at the same time.
2.4.Number of Staff and Engineers
Total number of stuff : 238
Total mechanical engineer :21

2.5.Functions of Mechanical Engineers in the Company

Mechanical engineers are seen in almost every part of production in UNTES. Beginning from the
product design to quality control after manufacturing, mechanical engineers have a lot of duties
in the company. These duties can be listed as follows:
1 Product design
2 Product analysis
3 Planning for operation sequences
4 Doing tests
5 Development of existing products
6 R&D
Moreover, mechanical engineers can be seen in administrative duties like management, buying,
planning, and so on.

2.6.Vision & Mission of UNTES

Vision

For the UNTES being leader company in HVAC field in national market

Product and service quality

Reliabilty

Share and continuity as in the pasts are basic princibles for healthy grow and reaching the
goals for the future.

Mission
UNTES is the national trademark with its principles for today. The aim is to become international
trademark with is known principles and become reliable trademark and get continuity trough
generations besides improving national image and market share.

2.7.Organizational Structure of the Company

See also Appendix A: organization chart of UNTES

3. MANUFACTURING STEPS
3.1. Inputs of the Factory
1

Profile materials

Steel Plates

Casting materials

Steel pipes

Machine production steel.

Motor

3.2. Processes
1

Cutting

Drilling

Turning

Milling

Pressing

Welding

Bending

Grinding

Heat Treatment

Shot-Blasting

PROCESS

MACHINING

lathes
milling cutter
incline mule
bohrwerk(boring machine)
driller grinding machine
Saw grinding machine
PROCESS

DRILLING
radial drilling machine
automatic profile driller
CNC cutting-drilling machine
Wagner drilling machine

PROCESS

SHOT-BLASTING
300x500 hor. shot-blasting
hand shot-blasting
500x1500 hor. Shot-blasting
perpendicular shot-blasting
shot-blasting machine

PROCESS

CUTTING
CNC plate shearing machines
NC plate shearing machine
optical plate shearing machine
CNC shear blades
combined shear blades
KV3 saw
band saws
plasma pipe cutting
shearing blade (2.5 meters)

PROCESS

PRESSING
CNC pres
press (2.5 meters)
hydraulic press
Cylinder
10

PROCESS

THREAD CUTTING
thread cutting machine

PROCESS

WELDING

Gas Metal Inert Welding

Submerged Welding Machine
Inverter Welding Machine

3.3. Production Flow

Firstly, technical drawings of work being made are drawn or have it brought from associate
company to technical drawing office in the plant. In here, work preparation sheets are formed
drawing computer based program. Work preparation consist duties being performed in each
production unit separately. Drawing papers are given to pre-manufacturing chief. At the same
time quality control management is informed about the project. With approval of quality
management manager, projects start in UNTES.
Pre-manufacturing chief determines the necessary materials and informs warehouse official chief
about them. At the same time, these inputs of the plant which are used in the certain project are
tested in quality assurance department. Basically, all materials are inspected after each production
unit by quality management system. Warehouse chief founds required materials and gives them
pre-sand blasting part of the plant. And then these materials are taken pre-manufacturing chief

11

responsibility. Cutting and drilling processes are made in these CNC and NC based machines.
Besides radial drilling machines, KV3 saws, band saws, optical shearing plate machine are used
depending on materials characteristics and machining properties and sensitivity. Additionally,
Chief divides and distributes materials in shares among workbenches taking into their activities. I
will give detailed information about each process and each property of these machines later on.
Sheared and drilled materials are marked these cutting and drilling workbench. Marking consists
of project number, pose number and foreman name that will take the materials and assemble with
his team. Besides grinding process has a part in pre-manufacture hole because of removing burr
on the steel plate or fin on a casting material causing of cutting and drilling process.
Plant manager distributes the duty to appropriate teams with respect to their qualifications. After
these processes, marked work pieces are being distributed to area of each foreman team.
Manufacturing chief now takes the responsibility of the work from pre-manufacturer. He watches
closely the products and their processes. As seen above that Organizational structure of this
procedure is quite hierarchical.
In manufacturing holes, there are 16 team and their welding units. Taken materials are preassembled by each team. And then quality control management controls each this pre-assembled
unit. Necessary measurements and observations are done by quality controllers who work both in
the name of UNTES and Cooperation Company. Controlled work piece assembled with various
welding techniques being mentioned later on. Also I will mention about the control techniques of
welded materials under their own title. Grinding, welding, annealing, assembling, some drilling
and cutting operations go on in these holes.
Finally, manufactured parts of some cement factory or mechanical equipments of the construction
area given the sand blasting machine generally. If the product dimensions are much higher than
machine, it is subjected to hand sand-blasting process. Smaller or the same size spherical steel
grains are used in final shot-blasting corresponding with pre-sand blasting process. Some errors
of the material appear after blasting. Burrs and fins of the materials are cleaned after these
procedures by grinding and emery.

12

4. PRODUCTION TECHNIQUES USED IN THE

ORGANIZATION
4.1. Material Removal Processes
In material removal processes, a sharp cutting tool is used to mechanically remove material to
achieve the desired geometry. This process is also called machining. As in all organizations,
machining is very important manufacturing process in UNTES, since almost all materials require
machining at some stage of their production.
The three principal machining processes are turning, drilling and milling. The other machining
operations include shaping, planing, broaching and sawing. The machining processes used in the
organization are: sawing, reaming, shaping, grinding, milling, drilling and related hole making
processes, turning, boring and related processes.
Machining is a manufacturing process in which a sharp cutting tool is used to cut away material
to leave the desired part shape. The predominant cutting action in machining involves shear
deformations of the work material to form a chip; as the chip is removed, a new surface is
exposed. Machining is most frequently applied to shape metals.
4.1.1 Cutting

Cutting processes are separated in different types.

4.1.1.1. Plasma Arc Cutting

13

The plasma arc process has always been seen as an alternative to the oxy-fuel process. In this part
of the series the process fundamentals are described with emphasis being placed on the operating
features and the advantages of the many process variants.
Process Fundamentals

The basic principle is that the arc formed between the electrode and the work piece is constricted
by a fine bore, copper nozzle. This increases the temperature and velocity of the plasma
emanating from the nozzle. The temperature of the plasma is in excess of 20 000C and the
velocity can approach the speed of sound. When used for cutting, the plasma gas flow is
increased so that the deeply penetrating plasma jet cuts through the material and molten material
is removed in the efflux plasma.
The process differs from the oxy-fuel process in that the plasma process operates by using the arc
to melt the metal whereas in the oxy-fuel process, the oxygen oxidises the metal and the heat
from the exothermic reaction melts the metal. Thus, unlike the oxy-fuel process, the plasma
process can be applied to cutting metals which form refractory oxides such as stainless steel,
aluminum, cast iron and non-ferrous alloys.
Power source
The power source required for the plasma arc process must have a drooping characteristic and a
high voltage. Although the operating voltage to sustain the plasma is typically 50 to 60V, the
open circuit voltage needed to initiate the arc can be up to 400V DC.
On initiation, the pilot arc is formed within the body of the torch between the electrode and the
nozzle. For cutting, the arc must be transferred to the workpiece in the so-called 'transferred' arc
mode. The electrode has a negative polarity and the workpiece a positive polarity so that the
majority of the arc energy (approximately two thirds) is used for cutting.
Gas composition
In the conventional system using a tungsten electrode, the plasma is inert, formed using argon, or
argon-H2, or nitrogen. However, oxidizing gases, such as air or oxygen, can be used but the
electrode must be copper with hafnium.

14

The plasma gas flow is critical and must be set according to the current level and the nozzle bore
diameter. If the gas flow is too low for the current level, or the current level too high for the
nozzle bore diameter, the arc will break down forming two arcs in series, electrode to nozzle and
nozzle to workpiece. The effect of 'double arcing' is usually catastrophic with the nozzle melting.
Cut quality
The quality of the plasma cut edge is similar to that achieved with the oxy-fuel process. However,
as the plasma process cuts by melting, a characteristic feature is the greater degree of melting
towards the top of the metal resulting in top edge rounding, poor edge squareness or a bevel on
the cut edge. As these limitations are associated with the degree of constriction of the arc, several
torch designs are available to improve arc constriction to produce more uniform heating at the top
and bottom of the cut.

4.1.1.2 CNC Oxy-Fuel Gas Cutting

In these machines the plates being formed are sheared by computer based machines. Basically,
plate beds to worktable and controlled by the workers. Machine switch is opened and oxygen, gas
valves are regulated according to their pressure. This pressure, cutting speed and nozzle table is
given in the appendix CNC-NC cutting machines. Cutting system is chosen in kind of oxygen or
plasma. The nozzles that are specific for all cut materials are attached. After this procedure,
relevant cutting program that is used opened in the computer and cutting process starts from
chosen reference point. This program is written by engineers in the disk and given to relevant
workers. Thickness of the sheared plate determines the flame and speed of nozzle. In plasma
cutting, thinner material than 50 mm is cut by plasma. Using plasma is much economic and
reliable but plasma nozzles have higher cost than oxygen. For this reason, once this nozzle is
damaged, it is hard to change. With oxygen, these machines cut the plates with thickness up to
200 mm. Cr-Ni alloying, aluminum, cast iron and Cu can not be cut by oxygen/ propane and
plasma type of shearing is applied for this type of plates.
4.1.1.3 Optical Oxy-Fuel Gas Plate Cutting Machine

15

This machine has the same principle with the CNC plate shearing machine but different based.
Pattern of the plate is drawn by the engineering department and given to relevant workers in
different to disk in the CNC. This 2 dimensional pattern are put the stationary black table and one
sensor that has capability to distinct white and black. This sensor follows the shape of patterns,
and nozzles cut the plates have the same shape. These machines older than CNC based machine
but it is more flexible than CNC. And it is usually used in more complex details.
4.1.1.3 Shearing

Shearing is the mechanical cutting of materials without the formation of chips by placing the
sheet between two edges of the shearing tools. If the blades are straight, the process is called
shearing, but if the blade geometry is curved, as in the edges of punches and dies, the process
have special names, such as blanking, piercing, notching and trimming. All of these are basically
shearing operations.
A simple type of shearing process is that the punch descends against the work piece then the
metal is first deformed plastically into the die. Because the clearance between the two tools is
only 5% to 10% of the thickness of the metal being cut, the deformation is highly localized. The
punch penetrates into the metal, the material flows into the die, and the opposite surface bulges
slightly. When penetration reaches about 15% to 60% of thickness of the metal, the amount
depending upon the material ductility and strength, the applied stress exceeds the shear stress and
the metal suddenly shears or ruptures through the remainder of its thickness.
Because of the normal inhomogeneities in a metal and the possibility of non-uniform clearance
between the shear blades, the final shearing does not occur uniformly. Fracture and tearing start at
the weakest points and proceed progressively and intermittently to the next stronger locations.
The result is a rough and ragged sheared edge.
If the punch and die have proper clearance and are maintained in good condition, sheared edges
may be produced that are sufficiently smooth to use without further finishing. The quality of the
sheared edge can be further improved if the strip stock is clamped firmly against the die from
above, the punch and die are maintained with proper clearance and alignment, and the movement
of the piece through the die is restrained by an opposing plunger or rubber die cushion applying
16

pressure from below the work piece. These measures cause the shearing to take place uniformly
around the edge rather than randomly at the weakest points. The major processing parameters in
shearing are the shape and materials for the punch and die, the speed of punching, lubrication and
the clearance between the punch and die.

4.1.1.4. Sawing
Sawing is a basic machining process in which chips are produced by a succession of small cutting
edges, or teeth, arranged in a narrow line on a saw blade. Each tooth forms a chip progressively
as it passes through the work piece, and the chip is contained within the space between two
successive teeth until these pass from the work. Because sections of considerable size can be
severed from the work piece with the removal of only a small amount of the material in the form
of chips, sawing is the most economical of the basic machining processes with respect to the
waste of material and power consumption, and in many cases with respect to labor. In recent
years vast improvements have been made in saw blades and sawing machines, resulting in
improved accuracy and precision of the process.

Sawing machine in UNTES

Circular saw and band saw are belonging to this group in UNTES. These saws can have different
kind of cutting shape. In these workbenches, hydraulics, air pressure and progress speed must be
arranged. Pipes, I-U beam and profiles are cut to desired length in these machines. Band saws can
cut larger materials than circle saws. In the band saws, maximum 620-1000 mm dimensions
materials are cut, where as in the circular saw machine maximum 450-500mm dimensional
materials are being cut. Disadvantage of the band saw is slower than the circular one. Horizontal
cutting saw machine cuts the angle bracket because of its fast and reliability.

4.1.2 Milling

17

Milling is a machining operation in which a workpart is fed past a rotating cylindrical tool with
multiple cutting edges (in rare cases, a too with one cutting edge, called a fly-cutter, is used). The
axis of rotation of the cutting tool is perpendicular to the direction of feed. This orientation
between the tool axis and the fees direction is one of the features that distinguish milling from
drilling. In drilling, the cutting tool is fed in a direction parallel to its axis of rotation. The cutting
tool in milling is called a milling cutter and the cutting edges are called teeth. The machine tool
that traditionally performs this operation is a milling machine.
The geometric form created by milling is a plane surface. Other work geometries can be created
either by means of the cutter path or the cutter shape. Owing to the variety of shapes possible and
its high production rates, milling is one of the most versatile and widely used machining
operations.
Milling is an interrupted cutting operation; the teeth of the milling cutter enter and exit the work
during each revolution. This interrupted cutting action subjects the teeth to a cycle of impact
force and thermal shock on every rotation. The tool material and cutter geometry must be
designed to withstand these conditions.
Types of milling operations
There are two basic types of milling operations;
a) peripheral milling
b) face milling
Peripheral milling
In peripheral milling, also called plain milling, the axis of the tool is parallel to the surface being
machined, and the operation is performed by cutting edges on the outside periphery of the cutter.
Types of peripheral milling:
Slab milling:
The basic form of peripheral milling; the cutter width extends beyond the workpiece on both
sides.
Slotting:

18

Slotting is also called slot milling. The width of the cutter is less than the workpiece width,
creating a slot in the work. When the cutter is very thin, this operation can be used to mill narrow
slots or cut a workpart in two, called saw milling.
Side milling:
The cutter machines the side of the workpiece.
Straddle milling:
The same as side milling, only cutting takes place on both sides of the work.
In peripheral milling, the rotation direction of the cutter distinguishes two forms of milling: up
milling and down milling. In up milling, also called conventional milling, the direction of motion
of the cutter teeth is opposite the feed direction when the teeth cut into the work. It is milling
against the feed. In down milling, also called climb milling, the direction of cutter motion is the
same as the feed direction when the teeth cut the work. It is milling with the feed.
The relative geometries of these two forms of milling result in differences in their cutting actions.
In up milling, the chip formed by each cutter tooth starts out very thin and increases in thickness
during the sweep of the cutter. In down milling, each chip starts out thick and reduces in
thickness throughout the cut. The length of a chip in down milling is less than in up milling. This
means that the cutter is engaged in the work for less time per volume of material cut, and this
tends to increase tool life in down milling.
The cutting force direction is tangential to the periphery of the cutter for the teeth that are
engaged in the work. In up milling, this has a tendency to lift the workpart as the cutter teeth exit
the material. In down milling this cutter force direction is downward, tending to hold the work
against the milling machine table.

Face milling
In face milling, the axis of the cutter is perpendicular to the surface being milled , and machining
is performed by cutting edges on both end and outside periphery of the cutter. As in peripheral
milling, various forms of face milling exist:
a) Conventional face milling: The diameter of the cutter is greater than the workpart
width, so that the cutter overhangs the work on both sides.
19

b) Partial face milling: The cutter overhangs the work on only one side.
c) End milling: The cutter diameter is less than the work width, so a slot is cut into the
part.
d) Profile milling: This is a form of end milling in which the outside periphery of a flat
part is cut.
e)

Pocket milling: Pocket milling is another form of end milling, this is used to mill

shadow pockets into the flat parts.

g) Surface contouring: A ball-nose cutter is fed back and forth across the work along a
curvilinear path at close intervals to create a three-dimensional surface form. The same basic
cutter control is required to machine the contours of molds and dies, in which case operations is
called die sinking.

4.1.3 Turning
Turning is a machining process in which a single point tool removes materials from the surface of
a rotating cylindrical workpiece; the tool is fed linearly in a direction parallel to the axis of
rotation. Turning is traditionally carried out on a machine tool called a lathe, which provides
power to turn the part at a given rotational speed and to feed the tool at a specified rate and depth
of cut.
Cutting Conditions in Turning CUTTING PRINCIPLE
:
The arbor can be made to revolve in either direction , but the tool will only cut in one
direction so the arbor must be checked to see that the direction is correct for the tool used. There
are two cutting principles:
Up milling is the most common .In this method the work moves in the opposite direction to the
rotation of the cutter. This produces the least chattering and the better surface.
Climb milling is used only where necessary. The work and tool move in the same direction.

20

The rotational speed in turning is related to the desired cutting speed at the surface of the
cylindrical workpiece by the equation:
Rotational speed (rev/min): N
Cutting speed (m/min): v
Original diameter (m): Do
N = v / Do
The turning operation reduces the diameter of the work from Do to final diameter Df. The change
in diameter is determined by the depth of cut d:
Do Df = 2d
The feed in turning is generally expressed in mm/rev. This feed can be converted to a linear travel
rate in mm/min by the formula:
fr = Nf
Where fr = feed rate (mm/min) and f = feed (mm/rev).
The time to machine from one of a cylindrical workpart to the other is given by
Tm = L/ fr
where Tm = time of actual machining(minutes); and L = length of the cylindrical workpart, mm.
As a practical matter, a small distance is usually added to the length at the beginning and end of
the workpiece to allow for approach and over travel of the tool.
The volumetric rate of material removal can be most conveniently determined by the following
equation:
MRR = vfd
Where MRR = material removal rate (mm3/min). In using this equation, the units for f are
expressed simply as mm, in effect neglecting the rotational character of turning. Also, care must
be exercised to assure that the units for speed are consistent with those for f and d.
Operations Related to Turning
A variety of other machining operations can be performed on a lathe in addition to
turning; these include the following:
a) Facing: The tool is feed radially into the rotating work on one end to create a flat

21

surface on one end.

b) Taper turning: Instead of feeding the tool parallel to the axis of rotation of the work,
the tool is fed at an angle, thus creating a tapered cylinder or conical shape.
c) Contour turning: Instead of feeding the tool along a straight line parallel to the axis
of rotation as in turning, the tool follows a contour that is other than straight, thus creating a
contoured form in the turned part.
d) Form turning: In this operation, sometimes called forming, the tool has a shape that
is imparted to the work by plunging the tool radially into the work.
e) Chamfering: The cutting edge of the tool is used to cut an angle on the corner of the
cylinder, forming what is called a chamfer.
f) Cutoff: The tool is fed radially into the rotating work at some location along its length
to cut off the end of the part. This operation is sometimes referred to as parting.
g) Threading: A pointed tool is fed linearly across the outside surface of the rotating
workpart in a direction parallel to the axis of rotation at a large effective feed rate, thus creating
threads in the cylinder.
h) Boring: A single-point tool is fed linearly, parallel to the axis of rotation, on the inside
diameter of an existing hole in the part.
i) Drilling: Drilling can be performed on a lathe by feeding the drill into the rotating
work along its axis. Reaming can be performed in a similar way.
j) Knurling: This is not a machining operation because it does not involve cutting of
material. Instead, it is a metal forming operation used to produce a regular crosshatched pattern in
the work surface.
Most lathe operations use single-point tools. Turning, facing, taper turning, contour
turning, chamfering, and boring are all performed with single-point tools. A threading operation
is accomplished using a single-point tool designed with a geometry that shaped the thread.
Certain operations require tools other than single-point. Form turning is performed with a
specially designed tool called a form tool. The profile shape ground into the tool establishes the
shape of the workpart. A cutoff tool is basically a form tool. Drilling is accomplished by a drill

22

bit. Knurling is performed by a knurling tool, consisting of two hardened forming rolls, each
mounted between centers. The forming rolls have the desired knurling pattern on their surfaces.

Stages of Drilling Operation in a Lathe

A lathe can be used to drill holes accurately concentric with the centerline of a cylindrical
part. First, a drill chuck is installed into the tailstock. It must be seen that that the tang on the back
of the drill chuck seats properly in the tailstock. The jaws of the chuck are withdrawn and the
chuck is tapped in place with a soft hammer. The saddle is moved forward to make room for the
tailstock. The tailstock is moved into position, and it is locked in place (otherwise it will slide
backward while drilling). Before starting the machine, spindle is turned by hand. The saddle is
moved forward, so it could interfere with the rotation of the lathe chuck. Always center drill must
be used to start the hole. Cutting fluid should be used with the center drill. It has shallow flutes
(for added stiffness) and doesn't cut as easily as a drill bit.
Always it should be drilled past the beginning of the taper to create a funnel to guide the bit in. At
most one or two drill diameters of material should be taken before backing off, clearing the chips,
and applying cutting fluid. If the drill bit squeaks, solvent is applied more often. The drill chuck
can be removed from the tailstock by drawing back the drill chuck as far as it will easily go, then
about a quarter turn more. A pin will press the chuck out of the collet.

4.1.4. Drilling

It is basically the production or enlarging of holes by the relative motion of a cutting tool and the
work piece that produce chips. The cutting tool, the work piece or both may rotate with the tool
generally being fed. Several methods of drilling exist, including conventional, deep-hole and small
hole drilling. While drilling is fast and economical, its cutting action is difficult and inefficient.
23

Cutting speed varies from a maximum at the periphery of the tool to zero at the center of the tool,
thus varying the load on the cutting edges. Both chip rejection and flow of the cutting fluid are
restricted in drilling. In addition, the production of small, deep holes can create problems with
respect to the necessary rigidity of the tools.
Cutting tools for drilling are rotary end cutting tools having one or more cutting lips and one
or more helical or straight flutes for the passage of the chips and the admission of the cutting fluid.
The most common are helical fluted twist drills with various shanks and tip geometries. Other types
include half-round, coolant-hole, spade and index able insert drills. So-called pivot drills are used
for small holes. Gun drills, pressure-coolant drills and trepanning tools are used extensively for
precision and deep hole operations.
Drilling is a complex three-dimensional cutting operation with conditions varying along the
entire cutting edge. While the outer edge of the drill produces chips by shearing, work piece
material under the chisel edge of the tool is subject to more severe deformation, thus requiring
greater thrust forces. Chip thickness, which varies with the feed rate, also has a major influence on
the chip formation. Increasing the feed, in turn the chip thickness, minimizes the possibility of the
flute clogging from coiled chips. Maximum feed, however, is limited by the structural strength of
the drill and the capacity of the machine.
Drilling has little effect on the physical properties of the work piece. There is a thin layer of
highly stressed material around the drilled hole, which is often removed, the surfaces may be more
susceptible to corrosion. Clamping of work pieces for drilling may also result in distortion.
The accuracy of any hole produced by drilling depends upon many factors, like the type of
the drilling process, the work piece, the tool and the machine used, operating parameters and the
rigidity of the setup. Accuracy is also dependent upon the sharpness and the geometry of the drill
point.

Drilling is a machining operation used to create a round hole in a workpart. In contrast with
boring that can only be used to enlarge an existing hole. Drilling is usually performed with a
rotating cylindrical tool which has two cutting edges on its working end. The tool is called a drill
or drill bit. The rotating drill feeds into the stationary workpart to form a hole whose diameter is

24

equal to the drill diameter. Drilling is customarily performed on a drill press, although other
machine tools can also perform this operation.
Cutting conditions in drilling
The cutting speed in a drilling operation is the surface speed at the outside diameter of the drill. It
is specified in this way for convenience, even tough nearly all of the cutting is actually performed
at lower speeds closer to the axis of rotation. To set the desired cutting speed in drilling, it is
necessary to determine the rotational speed of the drill for its diameter. Letting N represents the
spindle rev/min
N=v/D
Where v= cutting speed, mm/min; and D = the drill diameter, mm. In some drilling operations,
the workpiece is rotated about a stationary tool, but the same formula applies.
Feed f in drilling is specified in mm/rev. Recommended feeds are roughly proportional to drill
diameter; higher feeds are used with larger diameter drills. Since there are two cutting edges at
the drill point, the uncut chip thickness (chip load) taken by each cutting edges is half the feed.
Feed can be converted to feed rate using the same equation as for turning:
fr = Nf
Where fr = feed rate, mm/min.
Drilled holes are either through holes or blind holes. In through holes, the drill exits the opposite
side of the work; in blind holes, it does not. The machining time required to drill a through hole
can be determined by the following formula.
Tm = (t + A)/fr
where Tm = machining(drilling) time, min; fr = feed rate, mm/min; and A = an approach
allowance that accounts for the drill point angle, representing the distance the drill must feed into
the work before reaching full diameter. This allowance is given by
A= 0.5 D tan(90-
where A = approach allowance, mm; and = drill point angle.

25

In a blind hole, hole depth d is defined as the distance from the work surface to the point of the
hole. By this definition, the drill point angle allowance does not affect the time to drill the hole.
Thus for a drill hole, machining time is given by
Tm = d/ fr
The rate of the metal removal in drilling is determined as the product of the drill crosssectional area and the feed rate:
MRR = D2 fr /4
This equation is valid only after the drill reaches full diameter and excludes the initial approach
of the drill into the work.

Operations related to drilling

Several operations are related to drilling. Most of the operations follow drilling; a hole must be
made first by drilling, and then the hole is modified by one of the other operations. Centering and
spotfacing are exceptions to this rule. All of the operations use rotating tools.
a)

Reaming: Reaming is used to slightly enlarge a hole, to provide a better tolerance

on its diameter, and to improve its surface finish. The tool is called a reamer, and it usually has
straight flutes.
b)

Tapping: This operation is performed by a tap and is used to provide internal

screw threads on an existing hole.

c)

Counterboring: Counterboring provides a stepped hole, in which a larger diameter

follows a smaller diameter partially into the hole. A counterbored hole is used to seat bolt heads
into a hole so the heads do not produce above the surface.
d)

Countersinking: This is similar to counterboring, except that the step in the hole is

cone-shaped for flat head screws and bolts.

e)

Centering: Also called centerdrilling, this operation drills a starting hole to

accurately establish its location for subsequent drilling. The tool is called a centerdrilling.
Spotfacing: Spotfacing is similar to milling. It is used to provide a flat machined surface on the
workpart in a localized area.
26

4.1.5. Boring
Boring is similar to turning. It uses a single-point tool against a rotating workpart. The difference is
that boring is performed on the inside diameter of an existing hole rather than the outside diameter
of an existing cylinder. In effect, boring is an internal turning operation. Machine tools used to
perform boring operations are called boring machines. One might except that boring machines
would have features in common with turning machines; indeed as previously indicated, lathes are
sometimes used to accomplish boring.

Boring always involves the enlarging of an existing

hole, which may have been made by a drill or may be the result of a core in a casting. Concentricity
is an important attribute of bored holes. And so another important purpose of boring may be to
make the hole concentric with the axis of rotation of the work piece and thus correct any
eccentricity that may have resulted from the drills having drifted off the center line.
Boring can be made on horizontal, vertical or angular machines as long as the machine
design provides the inherent rigidity and accuracy to produce the tolerances required. Considerable
boring is done on the various types of lathes and also performed on some drilling machines.
Applications of boring can be divided into heavy cutting and precision operations. Heavy boring is
generally done on large horizontal and vertical boring machines. Precision boring is performed on
machines specially designed for this purpose. These machines generally take relatively light cuts,
maintain close tolerances and often capable of high production rates. Operations often performed
with precision boring in the same cycle include facing, turning and grooving. Machines are
sometimes arranged for accurate milling operations.
When boring is done in a lathe, the work usually is held in a chuck or on a faceplate. Holes
may be bored straight, tapered, or to irregular contours. Boring is essentially internal turning while
feeding the tool parallel to the rotation axis of the work piece.
Boring always involves the enlarging of an existing hole, which may have been made by a
drill or may be the result of a core in a casting. Concentricity is an important attribute of bored
holes. And so another important purpose of boring may be to make the hole concentric with the axis
of rotation of the work piece and thus correct any eccentricity that may have resulted from the
drills having drifted off the center line.
Boring can be made on horizontal, vertical or angular machines as long as the machine
design provides the inherent rigidity and accuracy to produce the tolerances required. Considerable
boring is done on the various types of lathes and also performed on some drilling machines.
27

Applications of boring can be divided into heavy cutting and precision operations. Heavy boring is
generally done on large horizontal and vertical boring machines. Precision boring is performed on
machines specially designed for this purpose. These machines generally take relatively light cuts,
maintain close tolerances and often capable of high production rates. Operations often performed
with precision boring in the same cycle include facing, turning and grooving. Machines are
sometimes arranged for accurate milling operations.
When boring is done in a lathe, the work usually is held in a chuck or on a faceplate. Holes
may be bored straight, tapered, or to irregular contours. Boring is essentially internal turning while
feeding the tool parallel to the rotation axis of the work piece.

4.1.6. Grinding
The grinding process is used to produce a high surface finish with a close tolerance and for
machining hard materials. The process is a variation of polishing using abrasive materials held
together by an adhesive generally in the form of a solid wheel. The wheel is rotated at high
speeds and the circumferential surface of the rotating wheel is brought into contact with the
material being machined.

The reasons for grinding are removal of surplus material, production of high quality
surface finishes and machining very hard materials
The two main abrasives used for grinding wheels are aluminum Oxide (for use on materials
with a high tensile strength) and silicon Carbide (for use on materials with a low tensile strength).
The grinding wheel variables including: abrasive material, bonding material, abrasive
particle size etc are selected depending on: required surface finish, metal removal rate, material,
wheel speed etc.
There are different types of grinding machines as shown below.

28

The surface grinder is used in the tool room for the production of accurate flat surfaces.
This machine has a similar layout to the horizontal milling machine but only removes small
thicknesses of material on the grinding passes.
The cylindrical grinding machine is use to generate cylindrical surfaces and is similar to a
centre lathe in appearance. The main difference is that the tool is replaced by a rotating grinding
wheel.
The centreless grinding machine is for pure cylindrical prism shapes which do not required
mounting. The workpieces are fed through two parallel rotating wheels: a conventional grinding
wheel and a rubberized regulating wheel. The regulating wheel is inclined at a slight angle to
facilitate axial movement.

Grinding is a material-removal process in which abrasive particles are contained in a bonded

grinding wheel that operates at very high surface speeds. The grinding wheel is usually diskshaped, and is precisely balanced for high rotational speeds.
Grinding can be likened to the milling process. Cutting occurs on either the periphery or the face
of the grinding wheel, similar to peripheral milling and face milling. Peripheral grinding is much
more common than face grinding. The rotating grinding wheel consists of many cutting teeth (the
abrasive particles), and the work is fed relative to the wheel to accomplish material removal.

The Grinding Wheel

A grinding wheel consists of abrasive particles and bonding material. The bonding material holds
the particles in place and establishes the shape and structure of the wheel. These two ingredients,
and the way they are fabricated, determine the parameters of the grinding wheel, which are:
1) Abrasive material
2) Grain size
3) Bonding material

29

4) Wheel grade
5) Wheel structure
These parameters are analogous to the material and geometry of a conventional cutting tool. To
achieve the desired performance in a given application, each of the parameters must be carefully
selected.
The amount of chip removal for each grinding wheel is as follows;

1st
(mm)

sideface

2nd sideface(mm)

1st grinding wheel

0,145

0,19

2nd grinding wheel

0,14

0,14

3rd grinding wheel

0,08

0,08

Grinding Operations and Grinding Machines

Grinding is traditionally used to finish parts whose geometries have already been created by other
operations. Accordingly, grinding machines have been developed to grind plain flat surfaces,
external and internal cylinders and contour shapes such as threads. The contour shapes are often
created by special formed wheels that have the opposite of the desired contour to be imparted to
the work. Grinding is also used in tool rooms to form the geometries on cutting tools. In addition
to these traditional uses, applications of grinding are expanding to include more high-material
removal operations. Our discussion of operations and machines in this section includes the
following types:
1) surface grinding
2) cylindrical grinding

30

3) centerless grinding
4) creep feed grinding
Surface Grinding
Surface grinding is normally used to grind plain flat surfaces. It is performed using either the
periphery of the grinding wheel or the flat face of the wheel. Since the work is normally held in a
horizontal orientation, peripheral grinding is performed by rotating the wheel about a horizontal
axis and face grinding is performed by rotating the wheel about a vertical axis. In either case, the
relative motion of the workpart is achieved by reciprocating the work past the wheel or rotating
it. These possible combinations of wheel orientations and workpart motions yield the four types
Of the four types, the horizontal spindle machine with reciprocating worktable is the most
common. Grinding is accomplished by reciprocating the work longitudinally under the wheel at a
very small depth and by feeding the wheel transversely into the work a certain distance between
strokes.
In addition to its conventional application, a grinding machine with horizontal spindle and
reciprocating table can be used to form special contoured surfaces by employing a formed
grinding wheel. Instead of feeding the wheel transversely across the work as it reciprocates, the
wheel is plunge-fed vertically into the work. The shape of the formed wheel is therefore imparted
to the work surface.
Grinding machines with vertical spindles and reciprocating tables are set up so that the wheel
diameter is greater than the work width. Accordingly, these operations can be performed without
using a transverse feed motion. Instead, grinding is accomplished by reciprocating the work past
the wheel and feeding the wheel vertically into the work to the desired dimension. This
configuration is capable of achieving very flat surface on the work.
Of the two types of rotary table grinding, the vertical spindle machines are more common. Owing
to the relatively large surface contact area between wheel and workpart, vertical spindle-rotary
table grinding machines are capable of high metal removal rates when equipped with appropriate
grinding wheels.

31

Cylindrical Grinding
As its name suggests, cylindrical grinding is used for rotational parts. These grinding operations
divide into two basic types:
- External cylindrical grinding
- Internal cylindrical grinding
External cylindrical grinding (also called center-type grinding to distinguish it from centerless
grinding) is performed much like a turning operation. The grinding machines used for these
operations closely resemble a lathe in which the tool post has been replaced by a high speed
motor to rotate the grinding wheel. There two types of feed motion possible, traverse feed and
plunge-cut. In traverse feed, the grinding wheel is fed in a direction parallel to the axis of rotation
of the workpart. A longitudinal reciprocating motion is sometimes given to either the work or the
wheel to improve surface finish. In plunge-cut, the grinding wheel is fed radially into the work.
External cylindrical grinding is used to finish parts that have been machined to approximate size
and heat treated to desired hardness. Parts include axles, crankshafts, spindles, bearings and
bushings and rolls for rolling mills. The grinding operation produces the final size and required
surface finish on these hardened parts.

Centerless Grinding
Centerless grinding is an alternative process for grinding external and internal cylindrical
surfaces. As its name suggests, the workpiece is not held between centers. This results in a
reduction in work handling time; hence, centerless grinding is often used for high production
work. The setup for external centerless grinding consists of two wheels; the grinding wheel and
a regulating wheel. The workparts, which may be individual short pieces or long rods are
supported by a rest blade and fed through between the two wheels. The grinding wheel does the
cutting. The regulating Wheel rotates at much lower speeds and is inclined at a slight angle to
control through feed of the work.

32

4.1.7. Piercing and Blanking

Piercing
Piercing is the operation of cutting internal features (holes or slots) in stock. Piercing can also be
combined with other operations such as lance and form (to make a small feature such as tab),
pierce and extrude (to make an extruded hole). All these operations can be combined with
blanking.
Piercing of all the holes is best done together to ensure good hole-to-hole tolerance and part
repeatability. However if the material distorts, the method described below can be done.
When there are large numbers of holes, in a tight pitch, there could be distortions, due to the high
amount of tension on the upper surface due to stretching and compression on the bottom surface.
This causes the material not to lay flat. This can be avoided/ lessened by staggering the piercing
of the holes. Holes are punched in a staggered pattern; then the other holes are punched in the
alternate staggered pattern.
Blanking
Blanking is cutting up a large sheet of stock into smaller pieces suitable for the next operation in
stamping, such as drawing and forming. Often this is combined with piercing.
Blanking can be as simple as a cookie cutter type die to produce prototype parts, or high speed
dies that run at 1000+ strokes per minute, running coil stock which has been slit to a specified
width.
For production parts, the final configuration of the drawn or formed shape needs to be established
before the blank die can be built-since the blank size and the slit width size needs to be
established precisely.
4.1.8 Tapping
Internal threads in work pieces can be produced by tapping. A tap is basically a threading
tool with multiple cutting teeth and they have usually three or four flutes. Chip removal can be a
significant problem during tapping because of the small clearances are involved .The difficulty of
tapping relative to other cutting operations is that tapping is severe requires low cutting speeds
and it needs effective cutting fluids.

33

4.2. Forming Operations

4.2.1. Bending
Bending is the plastic deformation of the metals about a linear axis with little or no change in the
surface area by stressing the metal above its yield strength but not larger than its ultimate tensile
stress. When multiple bends are made simultaneously with the use of a die, the process is
sometimes called forming. The various bend axes can be at angles to each other, but each axis
must be linear and independent of the others for the process to be classified as a true bending
operation. If the axes of deformation are not linear or are not independent, the process becomes
one of drawing and/or stretching, not bending. Characteristic of this process is stretching (tensile
elongation) imposed on the outer surface and compression on the inner surface. Since the yield
strength of metals in compression is somewhat higher than the yield strength in tension, the metal
on the outer side yields first, and the neutral axis is displaced from the center of the two surfaces.
Concerning the inner side of the bend, it is possible for the compressive forces to introduce
upsetting, which would cause the material to become longer in the direction parallel to the bend
axis. This effect can become quite pronounced in the bending of thick, narrow pieces.
Still another consequence of the condition of combined tension and compression is the tendency
of the metal to unbend somewhat after forming, a phenomenon known as spring back. To form a
desired angle, metals must be over bent in such a way that upon spring back, the material
assumes the desired shape of the product.

4.2.1.1. Angle Bending

A bar folder can be used to make angle bends up to 150 degree in sheet metal under about 1.5mm
in thickness. The sheet of metal is inserted under the folding leaf and moved to proper position.
Raising the handle then actuates a cam, causing the leaf to clamp the sheet. Further motion of the
handle then bends the metal to the desired angle. Bar folders are manually operated and are
usually less than 4meters long.

34

Bends in heavier sheet or more complex bends in thin material are generally made on press
brakes. These are mechanically or hydraulically driven presses with a long, narrow bed and
relatively slow, short, adjustable strokes. The metal is bent between interchangeable dies that are
attached to the bed and the ram. Different dies can be used to produce many types of bends. The
metal can be fed inward between successive strokes to produce various repeated bends, such as
corrugation. Seaming, embossing, punching, and other operations can also be performed by
inserting suitable dies into press brakes, but these operations can usually be done more efficiently
on other types of equipment when the volume is sufficient to justify their use.

4.3. Joining Processes

4.3.1. Welding
Welding is a process in which two materials, usually metals, are permanently joined together by
coalescence, the coalescence resulting from a combination of temperature, pressure, and
metallurgical conditions. The particular combination of temperature and pressure can range from
high temperature with no pressure to high pressure with no increase in temperature. Thus,
welding can be accomplished under a wide variety of conditions, and numerous welding
processes have been developed and are used routinely in manufacturing.

Nevertheless, the average person has little concept of the importance of welding as a
manufacturing process. If it were not for the use of welding, a large portion of our metal products
would have to be drastically modified, would be considerably more costly, or could not perform
as efficiently. In UNTES, such welding processes that are explained below are applied depending
on the desired strength, shape and time.

4.3.1.1. Oxyfuel Gas Welding

35

In oxyfuel gas welding, acetylene (C2H2) is used as fuel. A flame is directed towards the welding
point. The metals to be joined are melted at their joints during the process. Usually, materials are
thinner than 2mm are welded by this process. Mostly brass, silver and copper are welded by this
method; however iron can also be welded.

4.3.1.2. Arc Welding

In arc welding, both the electrode and the workpiece become part of an electric circuit. This
circuit causes an arc flow between the electrode and the work. This arc melts metals during
welding.

4.3.1.2.1. Shielded Metal Arc Welding (SMAW)

Shielded metal arc welding is performed by striking an arc between a coated-metal electrode and
the base metal. Once the arc has been established, the molten metal from the tip of the electrode
flows together with the molten metal from the edges of the base metal to forma sound joint. This
process is known as fusion. The coating from the electrode forms a covering over
the weld deposit, shielding it from contamination;

therefore the process is called SMAW.

The main advantages of shielded metal arc welding are that high-quality welds are made rapidly
at a low cost.
It is the most common arc welding process used in UNTES because of its low cost and wide
versatility. It provided a protective atmosphere and stabilizes the arc. These were the main
problems of early efforts of arc welding. Moreover, SMAW provides a protective coating to slow
the cooling of welding and prevent the oxidation. At the same time SMAW provides very good
penetration in welding process and used most commonly in thick metal plates.

4.3.1.2.2. Gas Tungsten Arc Welding (GTAW)

36

The primary difference between shielded metal arc welding and gas tungsten arc welding is the
type of shielding used. In gas tungsten arc welding, both the arc and the molten puddle are
covered by a shield of inert gas. The shield of inert gas prevents atmospheric
contamination, thereby producing a better weld. The primary gases used for this process are
helium, argon, or carbon dioxide. In some instances, a mixture of these gases is used.

4.3.1.2.3. Gas Metal Arc Welding (GMAW)

Gas metal arc welding (GMAW), formerly known as MIG welding (for metal inert-gas), was a
logical outgrowth of gas tungsten arc welding. The process is similar, but the arc is now
maintained between the workpiece and an automatically fed, consumable wire electrode.
Argon, helium, and mixtures of the two can be used for welding virtually any metal, they are
used primarily with the nonferrous metals. In welding steel, some O 2 or CO2 is usually added to
improve the arc stability and reduce weld spatter. The cheaper CO 2 can be used alone in welding
steel, provided that a deoxidizing electrode wire is employed.

The specific shielding gases can have considerable effect on the nature of metal transfer from the
electrode to the work and also affect the heat transfer behavior, penetration, and tendency for
undercutting (weld pool extending laterally beneath the surface of the base metal). Several types
of electronic controls can be used to alter the waveform of the current. This makes it possible to
control the mechanism of metal transfer, from drops, to spray, to short-circuiting drops. Some of
these variations include pulsed arc welding (GMAW-P), short-circuiting arc welding (GMAW-S),
and spray transfer welding (GMAW-ST). Buried arc welding (GMAW-B) is another variation in
which carbon dioxide-rich gas is used and the arc is buried in its own crater.
Gas metal arc welding is fast and economical because there is no frequent changing of electrodes,
as with stick-type electrodes. In addition, there is no slag formed over the weld, the process can
be readily automated, and, if done manually, the welding head is relatively light and compact. A
reverse-polarity DC arc is generally used because of its deep penetrated, spray transfer, and
smooth welds with good profile. Process variables include type of current, current magnitude,
shielding gas, type of metal transfer, electrode diameter, electrode composition, electrode stickout
(extension beyond the gun), welding speed, welding voltage, and arc length.
37

4.4. Surface Treatment and Finishing Processes

4.4.1. Sand Blasting

Sand blasting is a method for giving glass surfaces a matt finish either for decoration or to reduce
transparency. The method was invented in 1870 by an American, Benjamin C. Tilghman, who is
thought to have been inspired by the effect of sand being blown against windows on the
American prairies. Compressed air forces the abrasive material through the nozzle of a
sandblasting gun and onto the glass surface. Although sand can be used, more effective abrasives
with less toxic effects are now available. Silicon carbide is commonly used, as is electrocorundum (aluminum oxide). The glass is normally placed inside a special cabinet with arm
holes, a viewing window and dust extraction facilities.
Inputs of the plant (Profile materials, steel plates, steel pipes and machine production, rarely
casting materials) enter pre-sand blasting machines where in materials entering area. There are
three sand-blasting machines in here. Factory inputs are shot-blasted by spherical grid grains
bigger than main sand blasting grains which are applied before painting the materials. But this
factory is using steel shots with same size and quality in pre and final sand blasting. Steel plates
which will are blasted are carried with magnetic and winches to sand blasting machine area.
In UNTES, plates which have width up to 1500 mm and thickness up to 40 mm are being blasted
in horizontal machine. This machine has 300 mm height. Plates other than this size are blasted in
perpendicular sand blasting machine. If the perpendicular sand blasting machine is used,
hydraulic lifting apparatus are lifting plates to perpendicular position. Plates which have
thickness are less than 10 mm is bent in perpendicular position. Therefore, these plates are being
blasted also horizontal position.

38

Profiles and pipes are being pre-blasted after than cutting and drilling operations in horizontal
machines, generally. These factory inputs are carried with ceiling lifting winches and crosses to
pre-blasting area.
Available machines can not blast profile/pipe which is bigger than 500mm height/diameter and
plate which has width is more than 2500 mm. These materials are transmitted to manufacturing
area without any blasting operations.
On the other hand, final blasting of the work piece enables the painting well by getting surface
roughness on specific values. Therefore, painting materials wear and adhere to the surface of the
work piece.

4.4.2. Heat Treatment

Heat Treatment is the controlled heating and cooling of metals to alter their physical and
mechanical properties without changing the product shape. Heat treatment is sometimes done
inadvertently due to manufacturing processes that either heat or cool the metal such as welding or
forming.
Heat Treatment is often associated with increasing the strength of material, but it can also be used
to alter certain manufacturability objectives such as improve machining, improve formability,
restore ductility after a cold working operation. Thus, it is a very enabling manufacturing process
that can not only help other manufacturing process, but can also improve product performance by
increasing strength or other desirable characteristics.
Steels are particularly suitable for heat treatment, since they respond well to heat treatment and
the commercial use of steels exceeds that of any other material. Steels are heat treated for one of
the following reasons:
-Softening
-Hardening
-Material modification
39

In addition to this, U-I beams that are constructed in UNTES can de curved or bended after the
welding because of non homogeneous heat distribution. And some wrong dimensions appear as a
result of these. For this reason, with portable oxygen welding machine, annealing and material
modification is applied these beams.

4.4.2.1. Annealing Process

The term annealing refers to a heat treatment in which a material is exposed to an elevated
temperature for an extended time period and then slowly cooled. Ordinarily, annealing is carried
out to (1) relieve stresses; (2) increase softness, ductility, and toughness; and/or (3) produce a
specific microstructure.
Process annealing is a heat treatment that is used to negate the effects of cold work, that is, to
soften and increase the ductility of a previously strain-hardened metal.

5. COMPUTER NUMERICAL CONTROL

Altering the operating procedures of early NC systems required changing the hardware of the
machine tool itself. In the 1970s CNC systems, controlled by dedicated mini- or microcomputers,
were developed to enable machine tools to be readily adapted to different jobs by altering the
control program, or software. Consequently, CNC machine tools are easier to operate and more
versatile than their NC counterparts, and their programming is simpler and can be rapidly tested.
CNC systems can be used with a wide range of machine tools such as milling machines and
lathes. Some simulate tool movements, while others produce three-dimensional views of
components.

In UNTES bending, plasma cutting and shearing machines are CNC based. Many are equipped
with graphic displays that plot the shapes of the components being machined. Technical drawing

40

workshop gives the code of the workpiece which is being drilled or cut. In contrary to NC
machines, since they have less control hardware, they are cheaper to maintain and are generally
more accurate.

6. OPERATION SEQUENCES OF SOME PARTS

6.1. Flag:
1

A plate is sheared in the proper dimensions with Plasma Cutting Machine.

Piercing is done with CNC Punching Machine.

Grinding is done.

The piece is shot blasted.

It is galvanized.

Then it is painted.

After this the piece is sent to the furnace heat treated and dried, so the operation is
completed.

6.2. I-Beam:
1

A plate is again cutted into three proper parts with CNC Flame Cutting Machine.

These parts are sent to the Welded I-Beam Manufacturing Line.

Surface grinding is done.

The piece is shot blasted.

It is galvanized.

Then painted.

The I-Beam is sent to the furnace heat treated and dried, so the production of this piece is
completed.

6.3. Welded Platform:

1

A plate is again cutted into twelve pieces with proper dimensions with CNC Hydraulic
Cutting Machine.

These pieces are carried to welding department and welded together with Shilded Metal
Arc Welding Machine.

Surface grinding is done.

The platform is sent to shot blasting.

41

Then it is galvanized.

Painted.

After this operation it is sent to the furnace heat treated and dried, production is completed.

6.4. Joint Part:

1

A plate is sheared in proper dimensions with Guillotine Cutting Machine.

Four drills are created by Universal Drilling Machine.

The workpiece is bended by 90 with Abcant Hydraulic Press Machine:

Grinding is done.

Shot blasting is done.

The workpice is painted.

Then sent to furnace heat treated and dried, so the operation is completed.

6.5. Combined I-Beam Platform:

1 First a plate is cutted into seven proper parts with Guillotine Cutting Machine.
2 These parts are welded together to form a L-Shaped construction part.
3 Four drills with 10 mm diameters are created on the seventh part.
4 The seventh part is welded to the bottom of the short part of the L-Shaped construction
element with Arc Welding Machine.
5 Surface grinding is done.
6 Then the Combined I-Beam Platform is sent to the Shot Blasting.
7 Galvanization is done.
8 The construction part is painted.
9 It is sent to the furnace and so the production of this part is completed.

7. COST ANALYS FOR ONE CHOSEN PART:

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FAN-COIL BRIO IOP 20-30-35

NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

NAME OF PART
Brio 20 battery grill
Brio 20-30-35 fan
Internal back sheet
Internal feet (left-right)
Klemens
Battery top insulation tape
Internal left-right ins. tape
Bat. insulation rivetspring
Screw
Cable clips
Ground screw
Ground washer
Ground washer
Rivet
Graund label
Cardboard box
Stroke keeper
Stample
Electric label
Fancoil filter
Cark
Condenser frier
Condenser frier ins.tape
Top stick sheet
Internal side under ins.tape
BRIO 10-100 filter spring
Front-under sheet

QUANTITATIVE
1
1
1
2
1
1
2
2
30
1
1
1
1
2
2
1
4
8
1
1
1
1
1
1
2
2
1

COST
26
10
80cent
30cent
10 cent
80 cent
3
50cent
1
20 cent
10 cent
10 cent
10 cent
15 cent
60 cent
2,2
3
5
10cent
5
60cent
2
1
2
90 cent
60 cent
2

Unit cost is 66.5

Cost of one worker of one hour is 12 ytl
Total working hour is 2.6hour
Energy cost for one part is 0.5ytl
Labour is 31.2 ytl

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Total cost of chosen part is 148ytl

Gain=cost+cost*0.8
Sale price=gain+cost
Scale price=266ytl

8. CONCLUSION
The summer practice program has a big importance for mechanical engineering third year
students. A manufacturing company was entirely observed during this summer practice and of
some theoretical and practical knowledge about engineering drawing and production techniques
from the courses ME 113, ME 114, ME 203, ME 215 and ME216 which are given in the first and
second years was improved with practical applications. Also, an experience is gained in the real
working life. Students become more familiar with working conditions of a company.
Lots of beneficial knowledge is learned by the students. Firstly, students met with a lot of new
systems. Working principles, production procedures and importance of these steps are learned.
The systems of some unique and modern production techniques such as CNC operations were
carefully examined. The production steps of special parts were examined and the shortest and the
most economical way are learned. The general location of each production unit and the efficiency
of processes examined. The main differences between the modern and traditional manufacturing
techniques are practiced. These new systems provide students a researching and improving view.
The importance of engineering details was learned. The importance of technical drawings and
graphical representation were understood. Moreover, during this summer practice program
students improved their MS Office and Auto-CAD knowledge.
In conclusion, UNTES is a generally suitable company for ME 299 summer practice. Engineers
has usually good working conditions while workers have not that much. Besides, safety is
sometimes neglected by the workers. when the summer practice, four workers accident happened.
For better efficiency, UNTES should give more attention to systematic working and planning.
Also, there should be more controlling systems that are very important for decreasing operation
time of products.

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