1.

INTRODUCTION The object of the summer practice program for the junior year students is to familiarize them with various types of machines which they will meet after graduation. This program is also intended to acquaint the students with the practical and applied aspects of their theoretical engineering background they have acquired so far. Most of the students get a lot of theoretical information when they are studying at their departments before graduation. However, they do not know how to use this theoretical information to do some practical jobs. For this reason, this summer practice is very beneficial to the students, in that they have the chance to learn practical aspects of what they have learned before. In Akkardan A., there are different machines which are used for various processes. Different parts can be produced by using these machine tools. In the report the following topics will be presented: 1) Production system of the company 2) Description of the production techniques and properties of the machines and machine tools which are used in the factory 3) Machines which are used for some processes for part manufacturing and the steps 4) Technical drawings of sample workpieces produced by using machine tools and explanations of every stage in the production of parts. 5) Cost analysis of two products. Having represented the above topics, a conclusion where the data gained and the experience obtained during summer practice will be assessed. Finally, an appendix will be given. In this section all the related data will be presented.

1.1. GENERAL INFORMATION ABOUT THE COMPANY Name of the company: Akkardan San. Tic. A.. Company Location: E-5 Highway ayrova / Gebze Kocaeli Organizational and Duties of the engineers employed:

Mechanical Industrial Metallurgical Computer Environmental 1.2. BRIEF HISTORY

12 3 2 1 1

Production (5), Engineering Office (6), Quality Control (1) Engineering Office (1) Heat Treatment Dept(2), Quality Control Dept. (1) Engineering Office (1) Waste Disposal Dept. (1)

Akkardan A. was established in 1972 under the name of AkkardanSA which was a belonging of Hac mer Sabanc Holding A.. The company produces transmission shafts and other transmission products for cars, buses and trucks. Company is located 40 km to Istanbul and has an open area of 41500 m2. The quality and reliability of the company is documented with ISO 9002 and ISO 140001 by Bureau Veritas Quality International .Appendix 1-2 The products are imported to USA, Canada, Germany, Belgium, Finland, France, Dutch, England, Spain, Swiss, Switzerland, Italy, Norway, Greece, Persia, Saudi Arabia and Australia as an original or as an after market. In Turkey most of the truck, minibuses, buses and car factories are customers. The products of Akkardan A. are used by: * Ford Otosan * Mercedes Benz Turk, * Otokar (Magirus, Land Rover), * Otoyol (Iveco), * Anadolu Isuzu, * Askam, * BMC, * Temsa (Mitsubishi)

1.3. PARTS OF THE FACTORY * Chip removal Workshop * Heat Treatment Department * Assembly Workshop * Paint Room * Tool Department * Auxiliary Utilities 1.4. LIST OF THE PRODUCTS: propeller shafts with support bearing propeller shafts with sliding movement propeller shafts with sliding movement (Short design) Two pieces propeller shafts Three Pieces Steering Wheel Hub Wheel Axle Coupling Yoke Coupling Flange Companion Flange Companion Flange Cross Tooth Serration Flange Yokes End Yokes Tube Yokes Shaft Tube Couplings Spiders Tube Sleeves Slip Stop Shafts Yoke Shafts Yoke Stop Shafts Assy Yoke Stop Shafts Assy (Short Design) Midslip Stop Shafts Center bearing And supports Universal Joint Fixed Joint Slip Joint Axle Shaft Double Joint

2. PRODUCTION SYSTEM OF THE FACTORY The wrought irons which are coming from Omta, ukurova, Dkta and Ferrodkm are taken into storehouse. These wrought irons are examined by quality control department and checked their hardness, toughness and dimensional properties from their coming technical drawings and if it is okay they are approved. If planning department approves material is stored in the storehouse when it is needed planning department gives the job order and the wrought material is taken to chip removal workshop and manufacturing processes start. After needed operations done in chip removal workshop, product is sent to quality control department with. After the approval by the quality control work piece is sent to storehouse and waits for transporting to the company that gives the order. Some parts are assembled in assembly department and after assembly they are tested for balance and send to the companies.

2.1. Main Processes in Production 2.1.a. Turning Turning operations are done in 6 different marks of CNC machines. These are Mori Seiki, Mazak Hitachi Seiki, Daewoo, Takisawa and Gildemeister. In additions to them there are 2 special CNC machines Frontor Meisser for spider production and Diedsheim for putlog hole drilling on flanges. 2 methods are mainly used for supporting workpieces in CNC machines. The first one is holding in a chuck by jaws. If the workpiece is long it is held between centers, one in the spindle in a hole and the other in the tailstock. When it is held between centers the torque needed to rotate the workpiece is provided by lathe dog and dog plate. These equipments provide a connection between spindle and the work piece. If the work piece is hollow mandrels are used to provide the rotation. For work holding two additional methods are used in Akkardan A.., One of them which is developed in Akkardan A. is used in Morie Seiki CNC machines. A special apparatus is directly mounted on a chuck for producing coupling yoke and another device is interchanged with the chuck of Daewoo CNC machine in order to machine universal joint. This apparatus provides to rotate the workpiece (universal joint) 90 0 by this way the operator need not unload and load workpiece for every side. ZL CNC machines have two turrets. When one turret makes the rough turning the second one makes the finishing turning and this provides a 40%-50% of saved time. In Ford-Otosan production line, a special robot is assembled to the frontor weisser CNC machine. This robot handles the workpiece loads it to the chuck, unloads it from chuck, takes the workpiece from a special box and puts it after machining process. By the help of the special sensors this robot can warn the operator whether the storage box is empty of the other box for the finished products is full. Also in Diedsheim CNC machines in addition to putlog hole drilling and fine chamber this machine can make ring channel by the saggy rotation of the cutting tool.

The cutting tools used in CNC machines are selected according to the technical drawing of the workpiece and the data on them. Surface quality, roughness and radius dimensions are the main criteria for the selection of the cutting tools. After periods of time or after a number of workpieces are machined cutting tools are changed, in order to provide the desired quality. Some properties of MAZAK CNC machine is given in Appendix 3. 2.1.b. Broaching Broaching is the finishing of an entire surface with only one stroke. The geometry of broach is consisting of helical teeth whose diameter increases from the bottom end to the upper end and the distance between each tooth is called feed. The roughing teeth in the bottom end remove the material, the semi-finishing teeth provides surface smoothness and the last part of the broach, finishing teeth, produces an exact size of the material. In the factory 3 different types of broach is used. vertical broach horizontal broach cardinal broach When doing drilling, the work piece is clamped on to the machine and broach is passed through the hole of the workpiece and brings the hole in size and good surface finish. Broach teeth can be sharpened and for every sharpening it can broach 2000-20000 workpiece according to their hardness and other properties. Without chancing the tolerances one roach can be sharpened 8-10 times. Broaching speed changes between 1-8 m/min according to the properties of the workpiece. And this means that one workpiece can be broached in a 10-15 seconds time. Cardinal broach is done to the big workpieces such as MERCEDES, BMC truck and bus shafts. 2.1.c. Grinding In the grinding process we can sat that the dust on the workpiece is taken since the material removal rate is very low. In grinding processes grinding wheel rotates in opposite direction to the material and removes small grains from it while the grinding wheel is eroding itself. Since the chip removal rate is very low and the cutting speed is very big these two properties give grinding the ability to make very smooth surfaces. In order to prevent cutting ability in high temperatures cutting fluid is used. In the factory there are 2 grinding machine in the chip removal assembly and three CNC grinding machine in the TOYOTA production line. Grinding wheel is sharpened by a special diamonds in every cycle. Some properties of BLANCHARD grinding machine is shown in Appendix 4. 2.1.d. Drilling Drilling machines are used for drilling a hole by the help of revolving cutting tip. Some processes other than drilling can be done with drilling machines. These makes tapping, trepanning and threading. On drilling machines the working shaft supply tool to revolve and go towards the materials. 5

In Akkardan A.. there are universal drilling machines which can make translational in three axis x, y, z. These are Morie Seiki, Kitamura, Daewoo and Chiron mark machines. In the factory both CNC and mechanic drilling machines are used for drilling flange and break disks. Some properties of INFRETERIA drilling machine is given in Appendix 5. There is a special drilling machine whose name is Kitamura, Spark Changer, that it has two loading units. While drilling operation continues on one unit the operator loads and unloads the workpiece on the other unit. When the drilling operation is finishes the loading unit rotates 1800 and starts to drill the new clamped workpiece. In Daewoo drilling machine, drilling operation takes place in three axis namely x, y, z. also this machine have two loading units. Also in Hinges machine, which is a balancing machine decides where and how much depth to drill in order to provide the balance in the required axis. 2.1.e. Heat Treatment Heat treatment is used in order to change the hardness and toughness. In, heat treatment department, an inductor machine EMA is used to heat the workpiece up to 8000 C and then cool by water quenching. A spherical ring passes through the material without touching it. Since the temperature after the ring passes is above the recrystallization temperature after water quenching the form of the metal is transformed to martensite on the outer surfaces up to 3-4 mm depth. Depth of hardness is controlled by Vickerss or Brinells hardness test. By chancing the velocity or the current on the ring operator can adjust the depth and amount of hardness. Also by using oil instead of water cracks may be avoided in some materials. After induction and quenching workpiece should be annealed at 3000 C in a 24 hours time otherwise some detrimental effects may occur. 2.1.f. Rilsan Coating A special machine developed by Plascoat Systems Limited, is used for Rilsan Coating. First workpiece is dipped into tanks where in special solution exits, in order to clean the surface. After cleaning it is dried and heated up to 300 0C and dipped into the tank where rilsan powder exists. After a few seconds the material is taken off and the white colored powder changes it is color to dark blue while drying. This coating protects the workpiece from corrosion and other detrimental effects. The thickness of this coating changes from 0.5 - 1 mm. 2.1.g. Other Coatings The surfaces which are grinded before are covered with Mn-PO 4 coating in order to increase the surface quality. Zn-PO4 coating is used for the materials which are not working against corrosion.

3. PRODUCTION STAGES OF SOME PRODUCTS 3.1. Product 1: Wheel Axle 3.1.a. Operation 10 In this operation wrought material is machined by turning operation by a CNC machine, Gildemeister CTX 400 Serie 2.The flange part of the metal and spigot is machined. 4 types of cutting tool are used. The duration of operation is 63 seconds. You can see technical drawing of this product in Appendix 6. Table 1. Cutting tools for Wheel Axle and change periods for operation 10 Cutting Tool 1 Flange rough cutting 1/100 Cutting Tool 2 Flange finish cutting 1/250 Cutting Tool 3 Spigot rough cutting 1/250 Cutting Tool 4 Spigot finish cutting 1/500

The operator should control some of the dimensions and tolerances in a given period these are Outer diameter of the flange 3 times per 2 hours Length of flange 1 product per 30 product Flatness 3 per 2 hour

3.1.b. Operation 20 In this operation material coming from operation 10 is machined by turning operation by a CNC machine, Gildemeister CTX 400 Serie 2.In this operation for the thread hole rough hole is drilled by U-drill and tapping is done. 4 types of cutting tool are used. The duration of the operation is 59 seconds. Table 2. Cutting tools for Wheel Axle and change periods for operation 20 Cutting Tool 1 Cutting Tool 2 Cutting Tool 3 Cutting Tool 4 Finishing tool(full right part of material) 1/500

Thread hole emptying Grinding Diameter Punta Rough Turning 1/500 1/500 1/500

The operator should control some of the dimensions and tolerances in a given period these are Length 1 product per 50 product outer diameter1 product per 50 product 7

3.1.c. Operation 30 In this operation thread is done to the outer surface of the material. There are two rotating disks which are making tread onto the material. While the disks are rotating they also make a movement along the rotation axis. 3.1.d. Operation 40 Operation 40 is a grinding operation. The outer surface of the material is grinded. The grinding wheel rotates and can translate along the X-Z axes. There is a 200~210 angle between the grinding wheel and rotating material. After 25 materials are grinded the grinding wheel is sharpened with a special diamond. There is a control mechanism in grinding machine which is called marposs this device determines the feed of the grinding wheel. Total duration for this operation is 45 seconds. The operator should control some of the dimensions and tolerances in a given period these are: Outer Diameter.. ..1 product per 1 hour Flange diameter saggy. 3 product per 2 hours Spigot Diameter Concentricity 3 product per 2 hours Radius .3 product per 2 hours Surface quality .1 product per 30 products. 3.1.e. Operation 50 Operation 40 is a drilling operation. In this operation 4 position hole is done which is used afterwards for assembling. First a drill makes the hole for the thread after a guide hole is made and after them thread is done. 4 tread holes and 2 blind holes are machined. The operator should control some of the dimensions and tolerances in a given period these are: the position of the holes 3 product per 2 hours Thread control 1 product per 1 product Distance (4) 3 product per 2 hours

3.1.f. Operation 60 Up to operation workpiece is exposed to several forces and moments while rotating at high velocities, so there may some cracks occur during this operation. Since this power transmission products will be exposed to the same forces and torques in the future a small crack may propagate and may lead to some accidents. For this reason they are checked for cracks. Under the UV light a special solution which consists of water and fluorescent magnetic particle is poured onto the material and current is given to the material. For searching the cracks along the longitudinal direction 970 amperes is given to the material. The reliability of the fluorescent solution is tested by some methods, for example a test which is called Prof. Berthold Test is applied for checking the solution works or not. When we put Prof. Bertholds specimen into the solution under the UV light we should see all the cracks on it, it is the lower limit. Also the

solution is put into a centrifugal tube and the amount of fluorescent magnetic particle is checked it should be at least 1 gr / 100 ml. 3.2. Product 2: Otosan Hub 3.2.a. Operation 10 In this operation the first machining process is turning. This operation is done by a CNC machine named Takisawa TT 200. As we mentioned before this CNC machine is working with a handling robot which handles the wrought material from a special store box and loads this material to the CNC machine. The operator controls only whether the material box empty or the finished product box is full or not. Normally in this CNC machine two operations are done in the same time since this machine has two chuck which can work independent of each other while one of them machines the shank side of one material the other can machine the flange part of an another material. For Operation 10, 4 different cutting tools are used and the duration of machining progress is 13 seconds. You can see technical drawing of this product in Appendix 7. Table 3.Cutting tools for Otosan Hub and change periods for operation 10 Cutting Tool 1 Tool type Change period Shank Rough 1/85 Cutting Tool 2 Countersink 1/180 Cutting Tool 3 Hole rough 1/130 Cutting Tool 4 Outer Rough 1/160 Diameter

After the operation operator controls the following dimensions: Outer diameter 1/30 Length 1/30

3.2.b. Operation 20 The second operation is also a turning operation. Now the flange part of the hub is machined. The duration of machining process lasts 22 seconds Table 4.Cutting tools for Otosan Hub and change periods for operation 20 Cutting Tool 1 Flange Rough 1/70 Cutting Tool 2 Back emptying (Rough) 1/160 Cutting Tool 3 Cutting Tool 4 Cutting Tool 5 Flange (Finish) 1/165

side Back side Hole (Finish) emptying (Finish) 1/180 1/280

After the operation the operator controls the following dimensions: Inside Diameter..1/30 Outer Diameter.. 1/30 Length 1/30 Inner Diameter 1/10 Sag.. 1/10

3.2.c. Operation 30 This is a broaching operation. The name of the machine is Hipak and it is a vertical broach machine. In operation 20 the hole was drilled now it will be brought to exact size. The duration of the broach process is 20 seconds but since this broach machine have two broaches working in the same time, the machining time for one workpiece become 10 seconds. After the broaching process finishes the operator controls the following dimensions: * * * * Spline 1/10 Diameter Sag 1/1 Face sag 1/30 Broach Minor Diameter 1/30

3.2.d. Operation 40 In operation 40 the bearing face of the workpiece is grinded with a CNC grinding machine. The name of the grinding machine is Studer S36, made in Sweden. The grinding wheel moves along the x-z axes. The rotation of the workpiece and grinding wheel are in opposite directions. The angle between the grinding wheel and workpiece is 30. The control mechanism is provided by a device marposs. Marposs controls the position of the grinding wheel and stops the grinding wheels feed when necessary. The speed of the grinding wheel is 1620 rpm and there are 80 grains/cm2.Since grinding wheel also erodes while grinding the workpiece in after every 20 cycle grinding wheel is sharpened by a special diamond. After the grinding process the operator controls the following dimensions and tolerances: Length 1/30 Bearing diameter sag with respect to Spline diameter 1/30 Outer diameter 2 product / 2 hours Radius 1/20 Surface quality 1/20

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3.2.e. Operation 50 Operation 50 is turning operation. This machining process is done by a CNC machine named Gildemeister CTX 400 Serie2 .In this operation the flange and the spigot part of the workpiece is machined roughly and after rough cutting finishing cutting is done. The duration of the operation 50 is 46 seconds. In this operation 3 types of cutting tool is used. The table below shows the cutting tools and their change periods. Table 5. Cutting tools for Otosan Hub and change periods for operation 50 Cutting tool 1 Spigot Rough R0,8 1/150 Cutting tool 2 Spigot Finish R0,8 1/270 Cutting tool 3 Flange Finish R 0,8 1/120

After operation 50 the operator controls the following dimensions and tolerances with the given periods: Brake Disk rest face sag 3 workpiece / 2 hours Outer diameter (1) 1/30 Outer diameter (2) 5 workpiece/ 1 hour Length..1/30

3.2.f. Operation 60 Operation 60 is a drilling operation. This machining process is done by a CNC machine named Chiron Germany FZ12W.In this operation 5 holes and their countersinks are done which are radially equal distant from the center and have a 72 0 of angle between them. The drilling operations are done the CNC machine but the countersinks are done by hand machine not CNC. By this method while the machine is working the worker does not stop, he makes countersinks and this saves time. The duration of this process is 40 seconds. The drills used and their change period are given in the table below. Table 6.Cutting tools for Otosan Hub and change periods for operation 60 Cutting Tool 1 Drill 1/250 Cutting Tool 2 Countersink Drill 1/3000

After this drilling process the operator controls the following dimensions and tolerances: * Diameter of the Holes 1/1 11

*Positions of the holes

1/1

3.2.g. Operation 70 The last operation namely operation 70 is drop bolt pressing. In this operation 5 drop bolts are pressed in to the workpiece which acts as a fixed bolt and used for assembling the workpiece with the other power transmission parts to form shaft coupling.80 bar of press is used to mount the drop bolt onto the workpiece. After this operation the operator controls the following dimensions and tolerances: * Position of the drop bolts 1/1 by a position gage. 3.2.h. Operation 80 Since the workpiece is used in power transmission in cars and working under high forces and torques, a small crack or nonmetallic inclusion can act as a crack propagator. For this reason the last operation is crack control. As we mentioned before under the UV light a special solution which consist of water and fluorescent magnetic particle is poured onto the material and current is given to the material. For searching the cracks along the longitudinal direction 970 amperes is given to the material.

3.3. Product 3: Flange 3.3.a. Operation 10 Operation 10 is a turning operation. In this machining process the front part of the workpiece is machined by a CNC machine named Morie Seiki ZL 25.The outer diameter and the inner diameter of the front part is turned .The duration of this machining process is 1 minute 46 seconds. In this operation 4 types of cutting tool is used. The properties and the change period of these cutting tools are given in the following table. You can see technical drawing of this product in Appendix 8. Table 7.Cutting tools for Flange and change periods for operation 10 Cutting Tool 1 Outer diameter (Rough) 1/45 Cutting Tool 2 Outer diameter (Finish) 1/70 Cutting Tool 3 Inner diameter (Rough) 1/100 Cutting Tool 4 Inner diameter (Finish) Until Broken

After the machining process the operator controls the following dimensions and tolerances:

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* Hole Sag 1/10 * Length 1/30 * Outer Diameter 1/20 3.3.b. Operation 20 The second operation is back side turning of the flange. This operation is done by a CNC machine named Htachi 25 S. In this operation the back part of flange is machined. First the outer diameter of the flange is machined than by U-drill the inner diameter is machined roughly and at the end the finish cutting tool brings the inner hole to exact size with good surface finish. The duration of this operation is 2 minutes and 40 seconds. In this operation 3 cutting tools is used. The properties of them and change periods are given in the following table. Table 8.Cutting tools for Flange and change periods for operation 20 Cutting Tool 1 Outer Diameter & Shank Part Until Broken Cutting Tool 2 Cutting Tool 3

U-drill(Inner diameter)-Rough Inner Diameter (finish) 1/250 Until Broken

After this machining process the operator controls the following dimensions and tolerances: * Length. 1/30 * Inner Diameter 1/30 3.3.c. Operation 30 Operation 30 is a drilling and surface milling operation. This operation is done by a CNC machine named Daewoo ACE-V400. In this machine turret can move along the three axis namely, x-y-z. The first process is drilling 3 holes are drilled which are radially equal apart from the center and there is a 1200 angle between them. After drilling operation counter bore is done on to the bolt holes. When drilling operation finishes, milling operation starts. The first milling operation is done roughly and makes the surface smooth and the second milling process is done for bringing surface to exact size and improves the surface quality. In this operation 3 cutting tool is used. The table below shows the properties of the cutting tools and their change periods. Table 9.Cutting tools for Flange and change periods for operation 30 Cutting Tool 1 Drill 1/150 Cutting Tool 2 Milling (Rough) 1/150 Cutting Tool 3 Milling(Finish) 1/150

After the operation finishes the operator controls the following dimensions and tolerances:

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 Hole diameter 1/20 Position of the holes 1/20 After the third operation the workpiece is ready. 3.4. Product 4: Yoke Stop Shaft 3.4.a. Operation 10 The first operation is drilling operation and it is done by a CNC machine named Takisawa TC 20. First a deep hole extends from the back side to the front side is drilled by a U-drill. After this process the turret changes the cutting tool and machines the outer diameter of the back side of the work piece first roughly. After rough cutting turret selects finishing cutting tool and machines the same part and brings there into accurate size with good surface quality. When machining the outer diameter finishes turret selects another tool and roughly machines the inner diameter of the hole. At the end the hole is machined with finishing cutting tool and it is brought to exact size. The duration of Operation 10 is 1 minute 35 seconds. In this operation 4 types of cutting tool is used. The properties of these cutting tools and their change period are given in the table below. You can see technical drawing of this product in Appendix 9.

Table10. Cutting tools for Yoke Stop Shafts Assy and change periods for operation 10 Cutting Tool 1 Cutting Tool 2 Cutting Tool 3 Cutting Tool 4 U-Drill (Deep Hole) 1/25 Outer Diameter 1/25 Hole (Rough) 1/50 Hole (Finish) 1/50

After operation 10 the operator controls the following dimensions and tolerances: Hole Diameter 1/30 Outer Diameter 1/50

3.4.b. Operation 20 Operation 20 is broaching operation. In this operation the main hole of the work piece is broached in order to obtain spline. The name of the vertical broach machine is Varinelli which has two broaches. Verinelli is a pull-down type broach machine. The operator clamps the work pieces to the machine after the broaches go up, then presses the button and cutting fluid which helps broaches to go through the hole and cools down the work pieces begin to flow and broaches gives the shape of the hole and makes it spline. The top end and the bottom end of the broach position are controlled by switch mechanism. The duration of the broaching process for two work pieces is 35 seconds, so for one work piece it is 16 seconds.

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3.4.c. Operation 30 Operation 30 is putlog hole drilling. It is done by a CNC machine named Diedsheim which is a special machine for only putlog hole drilling and ring channel making. The workpiece is mounted by the back side and first putlog hole is drilled by two drills while the workpiece is stationary. When rough drilling of putlog hole is finished the same process is done with finishing cutting tool. After putlog hole is drilled, ring operation starts and by the saggy rotation of the cutting tool which is an incredible engineering intelligence. In the end the outer surface of the putlog hole is machined by milling. The duration of operation 30 is 50 seconds. The cutting tools used in this operation and their change periods are shown in the table below. Table 11. Cutting tools for Yoke Stop Shafts Assy operation 30 Cutting Tool 2 Milling 1/200 Cutting Tool 3 Putlog hole (finish) 1/200 and change periods for Cutting Tool 4 Ring making 1/300

Cutting Tool 1 U-drill (Putlog hole Rough) 1/300 3.4.d. Operation 40

The last operation is again broaching. The name of the broach machine is Arthur-Klink. This is a surface broaching machine with 2*2=4 loading unit and with two broaches. There is loading unit table which can rotate 3600 around itself. The operator first mounts two work pieces to the loading units and closes the protective window. After closing the window the switch mechanism gives information to the machine that the window is closed and the table turns 90 0. After turning of 900 broaches are pulled to the top and table turns again 90 0 to the same direction. At this point the switch mechanism open the locks of the protective window and operator unloads previous work pieces which are broached at the preceding cycle and loads the new work pieces while at the other side of the table work pieces are still broached. This machine is very practical for mass production. The duration for this process is 30 seconds. So for one workpiece the time required to be broached is 30/2=15 seconds.

3.5. Product 5: Tube Yoke 3.5.a. Operation 10 Operation 10 is drilling operation and it is done by a CNC machine named Daewoo SL220. At first a rough hole is drilled with U-drill which starts from the back side of the wrought material to the front end. After rough cutting the same hole is brought into accurate size with finishing cutting tool. When hole drilling finishes the outer diameter of the back side is machined. The duration of operation 10 is 1 minute 22 seconds. In this operation 4 types of cutting tool is

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used. The properties of these cutting tools and their change period are given in the table below. You can see technical drawing of this product in Appendix 10.

Table 12. Cutting tools for Tube Yoke and change periods for operation 10 Cutting Tool 1 U-drill 1/300 Cutting Tool 2 Inner (Finish) 1/250 Cutting Tool 3 Cutting Tool 4 Outer Diameter (Finish) 1/200

diameter Outer Diameter (Rough) 1/250

3.5.b. Operation 20 Operation 20 is a putlog drilling operation. This operation is done by a machine called Witzig / Frank. This machine is specialized for putlog drilling and it can also make some other chip removal processes. It has 4 cutting tools. There is a loading table which rotates along vertical axis. The operator opens the protective window unloads the finished workpiece and loads new workpiece then closes the window. In this process operation putlog hole is drilled then with saggy rotation of the cutting tool ring channel is machined first roughly and then with finishing tool. In the last turn the burnishing operations is done since the fit tolerances are very strict. The table below shows the cutting tools used in operation 20. Table 13.Cutting tools for Flange and change periods for operation 20 Cutting Tool 1 U-drill 1/200 Cutting Tool 2 Putlog Hole (Rough) 1/400-500 Cutting Tool 3 Putlog Hole (Finish) 1/100 Cutting Tool 4 Burnishing 1/400-450

After operation 20 the operator controls the following dimensions and tolerances: Bearing Diameter 1/1 Putlog Hole Sag 1/1

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4. CONCLUSION The most important aspect of ME 300 summer practice was to find a chance to study production techniques. At the same time, observation of interrelation between theoretical information about the machine tools and practical processes which are done at M.B.T is also important. Akkardan is the leading company factory in Turkey in shaft and other power transmission product production. It has a very worthy experience in shaft and other power transmission product production. For this reason it is well known among European countries as well as in Turkey. The most important benefit of trainees from this practice was to learn the application of technical information to practical processes. However, now it is seen that practical processes are as important as theoretical knowledge, because to be creative, in other words to be able to adjust the engineering senses to development of technologies. It is necessary for engineering that having theoretical information about machines and doing practice about these machines. During the summer practice Akkardan gave me the chance to observe the manufacturing technologies and processes. It is very important for me to see lots of manufacturing processes in an organization. In Akkardan A. the automation systems are not enough. To illustrate, the factory can have one more automation systems and observe the mass production rate increasing. During this summer practice, it is understood the importance of money in the life of company and engineers. The engineers should always pay attention to economy during design and production stages. Another important thing that it was learned is the relationship between people. An engineer should be very careful about his/her relations with his/her friends. These relations affect the performance of engineers.

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APPENDIX 1

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APPENDIX 2

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APPENDIX 3

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Machine Number: 072 IKD 003 Name : Special Equipped CNC Machine Firm : MAZAK

Pallet working area Table longitudinal stroke, X -axis Spindle head vertical stroke, Y-axis Column crosswise stroke, Z-axis Min. Distance from the spindle nose to the centre of pallet Max. distance from the spindle nose to the centre of pallet Min. Distance from the centre of spindle to the top surface of pallet Max. distance from the centre of spindle to the top surface of pallet Pallet load(evenly loaded): Max. drilling capacity Max. tapping capacity Max. milling capacity Spindle nose Spindle speed

800 mm * 800 mm(31.50 * 31.50 in.) 1300 mm(51.18 in) 1100 mm(43.31 in) 1000 mm(39.37 in) 200 mm(7.87 in) 1200 mm(47.24 in) 60 mm 1160 mm 2200 kg(4840 lbs) S45C 60 mm(2.36 in) S45C M52 P=5 800 cm/min (48.8 in/min ISO #50 35 to 7000 min Direct designation in units of 1 min 4-step gear shift (mechanical gear- 2 step, electrical gear- 2 step) 1 min. Rating 37kW 30 min. Rating 30 kW Continuous rating 22 kW

Main motor(AC inverter motor)

APPENDIX 4

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Machine Number: 034 IKS 002 Name :Surface Grinding Machine Firm :BLANCHARD

Table travel Max. width * Max. length of table T slots(no * width): T slot centre distance Max. operating thrust Max. weight on table

1350 mm 630 mm * 1750 mm 5 mm * 22 mm 100 mm 8000 kg 1800 kg

Feed control Permanent magnet d.c. table motor 5 hp Steady torque 10-2400 revs Dead slow speed 0-250 m/min High-speed travel 0-6000 m/min Variable work feed 10-2000 mm/min

APPENDIX 5

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Machine Number: 070 IKB 009 Name : Drilling Machine Firm : INFRETERIA Weight Height Length Width Conventional drilling diameter Drilling diameter in steel(*r=60 kg/mm) Drilling diameter in cast iron(*r=18 kg/mm) Drilling depth Drilling head maximum stroke on the column Main spindle maximum stroke Main spindle taper Distance between drill and column Max. distance between main spindle and worktable Max. distance between main spindle and base plate Work table area Number of Tslots on the work table Work table T-slots shape Base table area: Number of t-slots on the base table Base plate T-slots shape Main spindle head No. of Steps 12 1500 kg 2984 mm 1604 mm 770 mm 40 mm 40 mm 55 mm 280 mm 280 mm 280 mm Morse 5 355 mm 730 mm 1180 mm 500 mm * 630 mm 2 18 STAS 138550 635 mm * 610 mm 2 18 STAS 138550 STAS 165950

Main Spindle Speed Ratio Structural formula Speeds(rev/min) 1,41 2*2*3 31,5 45 63 90 125 250 355 500 710 1000 Machine Driving Power(kW) Speeds(rev/min) 4 1500 3000 0,150 Feeds(mm/rev) --20

Type Main motor Electric Pump

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APPENDIX 6

APPENDIX 7

APPENDIX 8

APPENDIX 9

APPENDIX 10

APPENDIX 11 COST ANALYSIS 1-) OTOSAN HUB Production Time=4 min 1) Engineering Cost=Number of Engineers involved in production x Average Engineer Salary x Time required for a product =3*(1650.000.000/24days/9 hour/60min)*4=1.527.000 TL 2) Total Material Cost =Indirect Material Cost (Transportation) + Material Cost =150.000 +650.000=800.000 TL 3) Labor Cost =Time needed for one product x workers salary =650.000.000*(4 min./60min/ 8 hours/24 days) =225.694 TL 4) Indirect Labor = Personnel Salary per product =150.000 TL 5) Energy = Time needed for one product x power consumed by machine *energy price = 4 min / 60.x 37 kW (See Appendix 3 for this term) x 126.600 TL =312.280 TL 6) Depreciation = Price of CNC machine over 5 years =250.000 Euro*1830.000/ 5years/ 365 days / 24 / 60 * 4 =696.347 TL 7) Other Expenditures = 1200.000 TL Total Cost = 4.911.321 TL

1-) Wheel Axle Production Time=3 min 1) Engineering Cost=Number of Engineers involved in production x Average Engineer Salary x Time required for a product =3*(1650.000.000/24days/9 hour/60min)*3=1.145.000 TL 2) Total Material Cost =Indirect Material Cost (Transportation) + Material Cost =150.000 +720.000=870.000 TL 3) Labor Cost =Time needed for one product x workers salary =650.000.000*(3 min./60min/ 8 hours/24 days) =169.270 TL 4) Indirect Labor = Personnel Salary per product =150.000 TL 5) Energy = Time needed for one product x power consumed by machine *energy price = 3 min / 60.x 37 kW (See Appendix 3 for this term) x 126.600 TL =234.210 TL 6) Depreciation = Price of CNC machine over 5 years (Mazak) =250.000 Euro*1830.000/ 5years/ 365 days / 24 / 60 * 4 =696.347 TL 7-) Other Expenditures = 1025.000 TL Total Cost = 3.264.827 TL

APPENDIX 12 Organization Chart

General Manager

Human Resources & Management Manager

Marketing Manager

Sales Manager

Financial Business Manager Businee

Quality Control Manager

Production Director

Production Manager

Engineering Manager

Production and Planning Manager

Maintenance Manager