aselsan staj

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INTRODUCTION

In mechanical engineering department the junior year students have some basic knowledge fromthe previously completed courses. In ME113 and ME114 mechanical engineering students got some

theoretical and practical knowledge about engineering drawing and also in ME!"! #Manufacturing$echnologies% they have learned theoretical data and practical applications of some. &owever thestudents have been told only a small part of these applications especially in ME!"! course.

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 organi'ation. Especially for the production

techni(ues 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. )lso the student gets some information about the speed mechanism capacity

and the fields of use of these machines. $here is one to one correspondence between

these increments band also the working principles of the machines. *uring the summerpractice the students can easily get answers to their problems and (uestions about the

details of the processes. Moreover in the company not only the students get some more

detailed information but also they see some industrial applications.

In this report you will see the detailed information that were mentioned above.

DESCRIPTION OF THE COMPANY

Company name:)selsan Military Electronics Industries Inc.

Company location: +) ,- 3" Etlik "/"11 )0)2)

Organiation !tr"ct"re o# t$e company:$he organi'ation structure of the

company is given in )++E0*I hart.

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N"m%er an& &"tie! o# engineer! employe&: In )kyurt facilities of )elsan 15

engineers are employed. 6" of them work in 2esearch and *evelopment #27*% /5 of

them in production 1" of them in planning and 1" of them in maintenance.

In +roduction Engineering *epartment there are 1! enginners 3 of whom are

mechanical engineer and the others are electrical engineers. ! of the mechanical

engineers are work in 27* and production the other engineer is interested in planning.

#)lso see )++E0*I%

Main area o# %"!ine!!:$here are three main divisions in )selsan. $he detailed

information about the area of business of each are mentioned below.

Comm"nication! Di'i!ion (CD)

$he ommunications *ivision is engaged in research8development8design

marketing8sales and production in the fields of military and civilian communications

e(uipment and systems electronic fuses power electronics and systems operations.

In its facilities located in Macunk9y and in its ,ranch offices in :stanbul and :'mir the divisionemploys a total of 11/! personnel of whom !5" are engineers. ;ithin the borders of $urkey there are 54provinces and !3 towns in which over 5"" outlets are in service


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=$actical )rea ommunications Fystems8$)FMF project is one of the biggest projects. ,y theimplementations of this project the $)C will become one of the first armies in the world using such a priorsystem and )selsan will become one of the world leading firms in this field.

$he +28451! Fhort 2ange Foldier 2adios which were originally developed for thecommunications re(uirements of the $urkish )rmed Corces s(uad members may also be used inshopping and business centers hotels and factories.

) contract has been signed in which )selsan will be producing the &ave Guick )vionics 2adios forthe ougar )F 53! helicopters which are to be produced in our country.

In order to fulfil the $urkish )rmed Corces? need the ME,F Integrated ommand ontrol Fystem#ME)% was developed and demonstrated for the first time at the ECEF?6 Military E@ercise. )selsan hasstarted taking orders for further productions.

$he development in the substructure for power electronics is continuing. )s a result of the co8operation with $JlomsaK )selsan has started designing and producing the electric8electronic systems oflocomotives. In 166 the ) *riving Fystems and &eat ontrolled carriage systems were developeddesigned and all deliveries completed. &aving a 5L share in $JlomsaK?s capital will increase the teamworkbetween two firms in the future years.

In the year 166 all the efforts made have brought about positive results within the $urkish2epublics in central )sia. $he sales of various products have reached a significant amount and sum in

)'erbaijan. )selsan has started its preparation for its new company which is to be constructed in ,akuand aims at increasing sales operating radio systems and making investment in the areas of production maintenance and repair. ) contract has been signed with 'bekistan for the sale of the 4""" seriesvehicular radio and base station. )nother contract made with yrghy'stan aims at improving thecommunications system of the police force in yrghy'stan by establishing an operational and secure radiosystem containing hand held vehicular radio and base station system with digital encryption.

$he * meets the re(uirements of the other departments of )selsan and gives service to e@ternalcustomers by using the available facilities in the electronical mechanical printed board and mouldingareas with the use of computer aided design #)*% and manufacturing #)M% capabilities.

;ithin the electronics production sections there are all kinds of boards modules cables coilsand transformers being produced to be used for civilian and military products. In addition to thiselectromechanical mounting and testing procedures are being kept up to international standards. ;ith theinvestment of the new reflow soldering machine the available FM* production line has been developedand testing "ability and capacity have been increased due to the investments made on new functionaltesting devices.

In the mechanical production and platingDpainting workshops mechanical parts are produced withthe use of precision 0 machine tools. In addition to this the plating and painting processes are madeaccording to the military standards and conductive painting processes are carried out on plastic usingsilver and nickel for electromagnetic protection. In 166 a variety of appro@imately 15"" parts wereproduced in these workshops in which the investment made on the and N8a@is numerically controlled

precision turn8mill center the video measuring system and the temperature and humidity controlledmeasuring room gave way to an increase in automation fle@ibility and precision as well as animprovement in (uality.

*ouble8sided multi8layer and fle@ible printed circuit boards are produced at the printed circuitboard production workshops which work according to the MI8+2C85511" an I+8/"1! standards. $heprinted circuit boards are produced with the selective solder plating and chemical nickel8gold platingprocesses in which all types of surface mount components are used. ;ith the investment on the vacuumpress in 166)selsan has started the production of printed circuit boards of up to 1/ layers.

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In order to produce the parts according to the (uality and precision re(uired by military standardssmall and medium type plastic injection molds metal cutting and shaping dies investment casting wa@moulds aluminium profile e@trusion dies aluminium injection moulds jigs and fi@tures are designed andproduced in the mechanical design directorate workshops.

166 was a year in which the * has increased its performance effectiveness and speed in theareas of sales services design and production and made valuable accumulations for coming years.

Micro*a'e an& Sy!tem Tec$nologie! Di'i!ion (MST)

$he Microwave and Fystem $echnologies #MF$% division located at Macunk9y facilities of)selsan provides total system solutions in the functional areas given belowO

Electronic warfare and intelligence

Cire support

Corward area air defense

Maneuver control

;ithin the framework of these functional areas MF$ division designs develops manufactures

and integrates sensor command and control communications and counter measures sub8systems ande(uipment for ground navy air platforms. MF$ division also provides military grade integrated logisticsupport services to its products throughout the life cycle of the e(uipment. E@amples of MF$ productspectrum are as followsO

Electric support measures #EFM% systems

Electric counter measures #EM% systems

Hround surveillance and artillery fire control radars

)rtillery mu''le velocity radars

)rtillery fire control systems and fire support automation systems

Cield artillery meteorology systems

+edestal mounted Ftinger systems

ommand and control consoles and terminals ommand and control information systems

Fensor fusion command and control systems

$he MF$ division applies its e@perience and technological knowledge accumulated throughmilitary programs in civil professional applications such as Motorway Emergency ommunications andontrol Fystems )utomatic $oll ollection Fystems Motorway -bservation Fystems and $raffic ontrolFystems. $he national fre(uency spectrum monitoring system project is another important application ofMF$ division?s capabilities in a civil professional area. In 166 MF$ entered into a challenging field whereit is able to apply its e@isting e@perience and technologiesO nmanned )ir Behicle #)B% Fystems forwhich the MF$ division with other divisions of )selsan shall provide command and control stations data8links and mission payloads.

$he key elements of MF$ division?s technological infrastructure can be summari'ed as followsO

) high technology computer aided new product development environment

) capable engineering work force speciali'ed in critical technologies

Manufacturing systems integration and test capabilities in military standards

Fystems engineering and project management e@perience in related fields

$hese elements are managed through a computer aided information system based on computernetworks and Intranet services to lead the division to the state of the art original products. Independent

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technology development programs various international data access channels Internet in companytraining programs can also be e@pressed as the e@amples of the important elements used to keep thedivision on the leading edge of technology.

;ithin its infrastructure and capabilities MF$ division successfully applies key technologies in itsproducts. In addition to system level analysis and design capabilities basic design and developmente@perience of the MF$ division is accumulated in the given fieldsO

Microwave and 2C circuits

)ntennas and transmission

)nalogue digital and mi@ed circuits including the design of )pplication Fpecific Integratedircuits #)FIs%

Electro8mechanical design including structural design and servo control design

Foftware design for real time applications

Electro warfare algorithms design

ommunications algorithms design

*igital signal processing applications

omputer and communications network applications

Information management applications

Engineering specialty areas such as reliability engineering electromagnetic compatibilityengineering etc. are also integrated to design and development activities through the system engineeringprocess. oncurrent engineering which has become a part of product development culture is now in atransmission process to the integrated product and process development approach.

)ll processes of the MF$ division are continuously improved in a total (uality managementprogram implemented teams. $he MF$ division also actively updates its capability maturity goals andmilestones for all its processes to provide the best products and services to its customers.

;ith these characteristics and capabilities the MF$ division is a reliable partner and a high (ualityproduct and service supplier for its domestic and international customers.

Microelectronic!+ ,"i&ance an& Electro-optic! Di'i!ion (M,EO)

In 1666the MHE- division is proud to continue supplying the $urkish )rmed Corcestechnologically advanced products with a total staff of 5 including 15 engineers and 41 specialists. Inthis conte@t various projects in areas of $hermal Imaging #I2% +assive 0ight Bision Inertial 0avigationHuidance aser and &ybrid Microelectronics have continued.

In 166 following products are successfully delivered against contractual schedulesA

I. generation $hermal Furveillance Fystems

II. generation $hermal Hunner Fights

II. generation )irdefence $hermal Fighting Fystems

II. generation Image Intensifier 0ight Bision E(uipment

ncooled $hermal ;eapon Fights

aser 2ange Cinders

aser +ointers

2ing aser Hyroscope Inertial 0avigation Fystems #2HDI0%

Electronic Huidance Fection of Ftinger Missile

&ybrid Microelectronics ircuits

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)lways having 2esearch 7 *evelopment #27*% in precedence developing new e(uipment andsystems applying advanced technologies and tracing developing technologies are )selsan?s objectives.;ith this vision 27* has reached a level to compete with other companies in international arena.

$he prototype for the $arget )c(uisition Fystem to be integrated to the ,aykuK $hermal ameraFystem in the $urkish )rmed Corces inventory has been completed and prepared for the serial productionstage. $he engineering and design effort for the Hround aser $arget *esignatorD2anger a re(uirementby the $urkish )ir Corces to be used together with the aser8Huided ,ombs has continued.

) fast prototyping workshop is established and integrated in to the )*D)M network. Cullautomation in design and manufacture of parts for investment casting and plastic injection processes areachieved.

,y using =hip 7 ;ire> technology the design and production capabilities for hybrid microcircuitsdevices in metal and ceramic packaged forms have been achieved for a semi8conductor packaging and=Multi8hip Modules> #MM% technologies.

In order to fulfil the avionic e(uipment re(uirements by the $urkish )rmed Corces 166 was ayear in which )selsan obtained the e@pected results of the efforts spent in this area. $hese avionics

e(uipment can be installed on almost all kinds of aircrafts including )B?s. 0ot only does )selsan fulfil thestrategic re(uirements of the $urkish )rmed Corces but also has a high potential for e@porting the abovementioned e(uipment. $he project work carried out on the )FECI28!"" Hyro8Ftabili'ed II. Heneration

)irborne $hermal Imaging Fystem and the 01""H H+F embedded 2ing aser Hyroscope Inertial0avigation Fystem had been completed in 166/. 166 started with the production and the engineeringinvestments of these e(uipment and continued into 166< in a status ready for production. ) contractsigned with the ndersecretariet for *efense Industries in 166 is based on the procurement of the

)FECI28!"" and 01""H e(uipment used for the ougar helicopters needed for the $urkish and and)ir Corces.

$he +hase8I delivery of 0863 2ing aser Inertial 0avigation Fystems produced for +eace -ny@8IIC81/ +rogram had been completed and deliveries for +hase8II started. In addition to this a contract wassigned for the e@portation of !" 0863 model 2HDI0F devices to the F). )selsan?s application made to

the F Hovernment for a (ualified source in 0863 project resulted with receiving a =Gualified Fourceertificate>.

Curthermore )selsan has entered into the field of manufacturing sophisticated Multi Cunction*isplay E(uipment embedded with moving map feature. ) future advancement to this capability is totalavionic integration. It is of great importance that the high8tech e(uipment and systems produced maintaintheir reliability and precision and be in contrast use throughout their lifetime. In order to meet thisobjective ogistic Fupport +lans were made to support the maintenance and repair of products andcomprehensive training provided to the customers. Bisits were made to the sites with customerrepresentatives where the e(uipment were used where e(uipment failures were evaluated at site andpreventative measures initiated. $he Hendarme Heneral ommand has ac(uired the ability for third andfourth level maintenance and repair of e(uipment regarding the ,aykuK $hermal amera and itsaccessories. ) similar contract has been signed with $urkish and Corces ommand for the ,aykuK and

0ight Bision e(uipment.)selsan participated in the working group of the nion of hambers 7 ommodity E@changes of

$urkey #$-,,% regarding )F which is one of the methods for the e@change of electronic information forlogistical purposes.

Intensive on8the8job seminars and skill training programs are being conducted according to theinternational and military standards to refresh the skills and recertify the employees in the MHE- *ivision.In addition end users and customer training are carried out for maintenance and repair of the deliveredsystems. &ence efficient and effective utili'ation of such e(uipment is ensured.

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.rie# $i!tory o# t$e company

)selsan was founded by $urkish )rmed Corces Coundation at the end of 165 to

produce tactical military radios and defense systems for $urkish )rmy.

$he first decisions taken at the foundation stage wereO

8)selsan will be a facility which is more developed than the other European factories.

8$he board of directors and auditors will be the young university graduated persons .

8onstruction will be started immediately and the facility will be functional in two years.

8$he first production will be started with foreign licensed.

8In order to improve the design of the new e(uipment a powerful 2esearch and

*evelopment division will be established.8Every year our facilities will be improved at the end a powerful *efensive Electronic

Industry will be established and )selsan have a part in 0)$- projects.

8$urkey will become an e@porting country rather than an importing country in the

*efensive Electronics.

In 16< )selsan signed a contract with $urkish )rmed Corces for tactical radio

family.

In early 166 following an investment and infrastructure establishment period

)selsan started its production at Macunkoy )nkara facilities.

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product spectrum. $, e@change systems field telephones and laser range finders

were among the new products.

)selsan contributed to the defense power of the $urkish )rmed Corces by its

Electronic ;arfare and *ata $erminals in 16


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In 1663 )selsan made a big achievement by establishing the Electro -ptics

$echnology enter at )kyurt Cacilities. )selsan (uality systems were certified in

accordance with IF-86""1 standards. Moreover in 1664 the )G)+84 certificate at

)selsan (uality system was revised as )G)+81 standards. &ave (uick radio production

started.

In 1665 in order to improve the customer services )selsan established regional

directorates. $he first abroad company was established as )selsan8,aku in )'erbaijan

in 166


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PRODUCTION TECHNI/UES IN THE FACTORY

FORMIN, OPERATIONS

.en&ing: ,ending is the plastic deformation of the metals about a linear a@is 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. ;hen multiple bends are made simultaneously

with the use of a die the process is sometimes called forming. Cor a given sheet

thickness h tensile and compressive strains increase with decreasing forming radius

Rb. $hus plastic irreversible bending differs from elastic reversible bending in that the

bend radius must be small enough to bring much of the sheet cross section into the

state of plastic flow. $he various bend a@es can be at angles to each other but each a@is

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must be linear and independent of the others for the process to be classified as a true

bending operation and be treatable by simple bending theory. If the a@es of deformation

are not linear or are not independent the process becomes one of drawing andDor

stretching not bending. haracteristic of this process is stretching #tensile elongation%

imposed on the outer surface and compression on the inner surface. Fince 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 a@is is displaced from the center

of the two surfaces. In fact the neutral a@is is generally located between one third and

one half of the way from the inner surface the precise location depending upon the

bend radius and the material. ,ecause of the preferred tensile deformation the metal is

thinned somewhat at the bend the thinning being more pronounced in the center of the

sheet where the material cannot freely pull in along the a@is of the bend.

oncerning 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 a@is. $his effect can become (uite pronounced in the bending of

thick narrow pieces.

Ftill another conse(uence of the condition of combined tension and compression

is the tendency of the metal to unbend somewhat after forming a phenomenon known

as springback. $o form a desired angle metals must be overbent in such a way that

upon springback the material assumes the desired shape of the product.

Angle %en&ing: ) bar folder can be used to make angle bends up to 15" in

sheet metal under Q in. thick. $he sheet of metal is inserted under the folding leaf and

moved to proper position. 2aising the handle then actuates a cam causing the leaf to

clamp the sheet. Curther motion of the handle then bends the metal to the desired angle.

,ar folders are manually operated and are usually less than 1! feet #4 meters% long.

,ends in heavier sheet or more comple@ bends in thin material are generally

made on press brakes. $hese are mechanically or hydraulically driven presses with a

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long narrow bed and relatively slow short adjustable strokes. $he metal is bent

between interchangeable dies that are attached to the bed and the ram. *ifferent dies

can be used to produce many types of bends. $he metal can be fed inward between

successive strokes to produce various repeated bends such as corrugation. Feaming

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 e(uipment when the volume is sufficient to justify their use.

S$earing:Fhearing is the mechanical cutting of materials without the formation

of chips by placing the sheet between two edges of the shearing tools. ;hen the blades

are straight the process is called shearing. ;hen the blade geometry is curved as in

the edges of punches and dies the process have special names such as blankingpiercing notching and trimming. )ll of these are essentially shearing operations

however.

) simple type of shearing process is that the punch descends against the

workpiece then the metal is first deformed plastically into the die. ,ecause the clearance

between the two tools is only 5L to 1"L of the thickness of the metal being cut the

deformation is highly locali'ed. $he punch penetrates into the metal the material flows

into the die and the opposite surface bulges slightly. ;hen penetration reaches about

15L to /"L of thickness of the metal the amount depending upon the material ductility

and strength the applied stress e@ceeds the shear stress and the metal suddenly

shears or ruptures through the remainder of its thickness.

,ecause of the normal nonhomogeneities in a metal and the possibility of non8

uniform clearance between the shear blades the final shearing does not occur

uniformly. Cracture and tearing start at the weakest points and proceed progressively

and intermittently to the ne@t stronger locations. $he result is a rough and ragged

sheared edge.

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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. $he (uality 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 pressure from below the workpiece.

$hese measures cause the shearing to take place uniformly around the edge rather than

randomly at the weakest points. $he 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.

MACHININ, OPERATIONS

T"rning:$his process consists of machining an e@ternal cylindrical surface with a

single8point tool while the workpiece is rotating and with the tool moving parallel to the a@is

of the workpiece at a prescribed depth and speed to remove the outer surface of the

workpiece. It is usually performed on a lathe. If the tool is fed at an angle to the a@is of

rotation an e@ternal conical surface results. $his is called taper turning.

$urning constitutes the majority of lathe work. $he cutting forces resulting from

feeding the tool from right to left should be directed toward the headstock to force the

workpiece against the workholder and thus provide better work support.

If food finish and accurate si'e are desired one or more roughing cuts usually are

followed by one or more finishing cuts. 2oughing cuts may be as heavy as proper chip

thickness tool life lathe horsepower and the workpiece permit. arge depths of cut and

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smaller feeds are preferred to the reserve procedure because fewer cuts are re(uired and

less time is lost in reserving the carriage and resetting the tool for the following cut.

.oring:,oring always involves the enlarging of an e@isting hole which may have

been made by a drill or may be the result of a core in a casting. )n e(ually important and

concurrent purpose of boring may be to make the hole concentric with the a@is of rotation

of the workpiece and thus correct any eccentricity that may have resulted from the drill?s

having drifted off the center line. oncentricity is an important attribute of bored holes.

,oring can be made on hori'ontal vertical or angular machines as long as the

machine design provides the inherent rigidity and accuracy to produce the tolerances

re(uired. onsiderable boring is done on the various types of lathes and also performedon some drilling machines.)pplications of boring can be divided into heavy cutting and

precision operations. &eavy boring is generally done on large hori'ontal and vertical

boring machines. +recision boring is performed on machines specially designed for this

purpose. $hese machines generally take relatively light cuts maintain close tolerances

and often capable of high production rates. -perations often performed with precision

boring in the same cycle include facing turning and grooving. Machines are sometimes

arranged for accurate milling operations.

;hen boring is done in a lathe the work usually is held in a chuck or on a face

plate. &oles may be bored straight tapered or to irregular contours. ,oring is essentially

internal turning while feeding the tool parallel to the rotation a@is of the workpiece.

Facing:Cacing is the producing of a flat surface as the result of a tool?s being fed

across the end of the rotating workpiece. nless the work is held on a mandrel if both end

of the work are to be faced it must be turned end for end after the first end is completed

and the facing operation repeated.

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$he cutting speed should be determined from the largest diameter of the surface to

be faced. Cacing may be done either from outside inward or from the center outward. In

either case the point of the tool must be set e@actly at the height of the center of rotation.

In facing the tool feeds perpendicular to the a@is of rotating workpiece. ,ecause the

rpm is constant the speed is continually decreasing as the a@is is approached.

0n"rling: nurling produces a regularly shaped roughened surface on a

workpiece. )lthough knurling also can be done on other machine tools even on flat

surfaces in mot cases it is done on e@ternal cylindrical surfaces using lathes. nurling is a

chipless cold8forming process. $he two hardened rolls are pressed against the rotating

workpiece with sufficient force to cause a slight outward and lateral displacement of themetal so as to form the knurling in a raised diamond pattern.

Tapping: Internal threads in workpieces can be produced by tapping. ) tap is a

basically a threading tool with multiple cutting teeth. $aps are generally available with three

or four flutes. hip removal can be a significant problem during tapping because of the

small clearances involved. If chips are not removed properly the resulting e@cessive

forces can break the tap.

Drilling:It is basically the production or enlarging of holes by the relative motion of

a cutting tool and the workpiece which produce chips. $he cutting tool the workpiece or

both may rotate with the tool generally being fed. Feveral methods of drilling e@ist

including conventional deep8hole and small hole drilling. ;hile drilling is fast and

economical its cutting action is difficult and inefficient. utting speed varies from a

ma@imum at the periphery of the tool to 'ero at the center of the tool thus varying the load

on the cutting edges. ,oth 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.

utting 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

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the cutting fluid. $he most common are helical fluted twist drills with various shanks and tip

geometries. -ther types include half8round coolant8hole spade and inde@able insert drills.

Hundrills pressure8coolant drills and trepanning tools are used e@tensively for precision

and deep hole operations. Fo8called pivot drills are used for small holes. *rilling is a

comple@ three8dimensional cutting operation with conditions varying along the entire

cutting edge. ;hile the outer edge of the drill produces chips by shearing workpiece

material under the chisel edge of the tool is subject to more severe deformation thus

re(uiring greater thrust forces. hip thickness which varies with the feed rate also has a

major influence on the chip formation. Increasing the feed in turn the chip thickness

minimi'es the possibility of the flute clogging from coiled chips. Ma@imum feed however is

limited by the structural strength of the drill and the capacity of the machine.

$he accuracy of any hole produced by drilling depends upon many factors like thetype of the drilling process the workpiece the tool and the machine used operating

parameters and the rigidity of the setup. )ccuracy is also dependent upon the sharpness

and the geometry of the drill point.

*rilling has little effect on the physical properties of the workpiece. $here is a thin

layer of highly stressed material around the drilled hole which is often removed the

surfaces may be more susceptible to corrosion. lamping of workpieces for drilling may

also result in distortion.

Milling: Milling is a basic machining process by which a surface is generated

progressively by the removal of chips from a workpiece fed into a rotating cutter in a

direction perpendicular to the a@is of the cutter. It is indispensable for the manufacture of

parts of non8rotational symmetry. In nearly all cases a multiple tooth cutter is used so that

the material removal rate is high. -ften the desired surface is obtained in a single pass of

the cutter or work and because very good surface finish can be obtained milling is

particularly well suited to and widely used for mass8production work. Feveral types of

milling machines are used ranging from relatively simple and versatile machines that are

used for general purpose machining in job shops and tool8and8die work to highly

speciali'ed machines for mass production. n(uestionably milling than any other

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machining process produces more flat surfaces. $he cutting tool used in milling is known

as a milling cutter.

Milling operation can be classified into two broad categories called peripheral milling

and face milling.

In peripheral milling the surface is generated by teeth located on the periphery of

the cutter body. $he surface is parallel with the a@is of rotation of the cutter. ,oth flat and

formed surfaces can be produced by this method the cross section of the resulting

surface corresponding to the a@ial contour of the cutter. $his process is often called slap

milling and is usually performed on hori'ontal spindle machines.

In face milling and end milling the generated surface is at right angles to the cutter

a@is. Most of the cutting is done by the peripheral portions of the teeth with the face

portions providing some finishing action. Cace milling is done on both hori'ontal8spindle

and vertical8spindle machines.

In milling surfaces can be generated by two distinctly different methodsA up milling

and down milling. up milling is the traditional way to mill and is called conventional milling.

$he cutter rotates against the direction of the workpiece. In climb or down milling the

rotation is in the same direction as the feed. $he method of chip formation is completely

different in the two cases. In up milling the chip is very thin at the beginning and increases

in thickness becoming a ma@imum where the tooth leaves the work.

In down milling ma@imum chip thickness occurs close to the point at which the

tooth contacts the work. ,ecause the relative motion tends to pull the workpiece into the

cutter any possibility of looseness in the table feed screw must be eliminated if down

milling is to be used. It should never be attempted on machines that are not designed for

this type of milling.

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Sa*ing:Fawing is a cutting operation in which the cutting tool is a blade having a

series of small teeth with each tooth removing a small amount of material. $his process is

used for all metallic and nonmetallic materials that are machinable by other cutting

processes and is capable of producing various shapes. ,ecause sections of considerable

si'e can be severed from the workpiece with the removal of only small amount of the

material in the form of chips sawing is probably 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.

Filing:,asically the metal8removing action in filing is the same as in sawing in that

chips are removed by cutting teeth that are arranged in succession along the same plane

on the surface of a tool called a file. $here are two differencesA #1% the chips are verysmall and therefore the cutting action is slow and easily controlled and #!% the cutting

teeth are much wider. onse(uently fine and accurate work can be done.

1OININ, OPERATIONS

,a! Metal Arc 2el&ing: Has metal arc welding #HM);% formerly known as MIH

welding #for metal inert8gas% was a logical outgrowth of gas tungsten arc welding. $he

process is similar but the arc is now maintained between the workpiece and an

automatically fed consumable wire electrode.

)rgon helium and mi@tures of the two can be used for welding virtually any metal

they are used primarily with the nonferrous metals. In welding steel some -!or -! is

usually added to improve the arc stability and reduce weld spatter. $he cheaper -!can

be used alone in welding steel provided that a deo@idi'ing electrode wire is employed.

$he 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 e@tending laterally beneath the

surface of the base metal%. Feveral types of electronic controls can be used to alter the

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19/38

waveform of the current. $his makes it possible to control the mechanism of metal transfer

from drops to spray to short8circuiting drops. Fome of these variations include pulsed arc

welding #HM);8+% short8circuiting arc welding #HM);8F% and spray transfer welding

#HM);8F$%. ,uried arc welding #HM);8,% is another variation in which carbon dio@ide8

rich gas is used and the arc is buried in its own crater.

Has metal arc welding is fast and economical because there is no fre(uent

changing of electrodes as with stick8type 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. ) reverse8polarity * arc is generally used because

of its deep penetrated spray transfer and smooth welds with good profile. +rocess

variables include type of current current magnitude shielding gas type of metal transferelectrode diameter electrode composition electrode stickout #e@tension beyond the gun%

welding speed welding voltage and arc length.

) number of industrial robots are now available to perform gas metal arc welding.

$o function properly however the computer electronics of these robots must be shielded

from the high8fre(uency interference of the welding process.

Spot 2el&ing: Fpot welding is making spots between two pieces of metal without

re(uiring access to both sides of the joint. $he duration of arcing is automatically timed so

that the two workpieces are heated sufficiently to form an acceptable spot weld. $he depth

and si'e of the weld nugget are controlled by the amperage time and type of shielding

gas

FINISHIN, OPERATIONS

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20/38

San& .la!ting:In sand blasting the abrasive is carried by an air stream or water

stream and strikes the surface at a high velocity. It removes scale burrs8light fins and rust.

$he abrasive is propelled by paddles which throw the grit onto the work either by

centrifugal action or by a blast of air which picks up the abrasive and carries it through the

pipe or hose on through a no''le. $his process economically cleans castings and welded

steel parts.

Han& (Man"al) De%"rring:It is an operation in which a handled deburring tool is

used or in which a handled part is placed against a fi@tured tool. &and deburring is still

used e@tensively eventhough it is slow labor intensive and costly and often provides less

consistent results than desired. )dvantages of hand deburring include the versatility of the

process and minimal capital investment.

,rin&ing:Hrinding is a chip removal process and the cutting tool is an individual

abrasive grain. $he major differences between grain and single8point cutting tool actions

are that individual grains have irregular shapes and are spaced randomly along the

periphery of the whell. $he average rake angle of the grains is highly negative. Each

abrasive grain removes a small chip. $hese chips are much smaller than those obtained in

metal cutting operations in general. Curthermore because of deformation the actual chip

will be shorter and thicker than the calculated values. ,ecause of small dimensions

involved forces in grinding are much smaller than those in cutting operations. Hrinding

forces should be kept low in order to avoid distortion and to maintain dimensional accuracy

of the workpiece.

MACHINES IN THE MACHINESHOP

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21/38

#$he technical information of the machines are given at )ppendi@%

.ay3al ,"illotine: $his is a very simple cutting machine. It is very simple to use

and control. In the machineshop it is used for cutting small and thin sheet materials. It has

a hand8operated arm.

.ay3al .en&ing .ra3e: $his bending brake is usually used to form sheet

materials. nlike the other bending brakes it can be used for (uite large si'e sheets. It

has immediate and very simple control. $his bending brake can carry out forming and

straightening. )lso it is very rigid accurate and rapid. Moreover it has a fi@ed bottom

beam a return tonnage a long stroke and a great distance between top8beam and

bottom8beam.

Aciera ET4 Preci!ion Tapping Mac$ineO $his is a precision tapping machine that

is suitable for sensitive small tapping work and has a sensitive clutch that enables the

machine to be used in micro mechanics. $he spindle driven via a two8step pulley is

running in bron'e bearings. $he machine has an adjustable tapping depth and the tapping

device operates by means of friction cone couplings. $hese couplings can be adjusted

fle@ibly so that it can also be used for making precision components and clock making.$he top of the machine can be swiveled between column and motor in this way the base

can be used as a second table. $he driving motor can be moved on the based to tighten

the belt. $he additional technical data is given in )ppendi@ ,.

Aciera 54 T5E Sen!iti'e Drilling Mac$ine:$his machine is a small high speed

machine consists of an upright standard a hori'ontal table and a vertical spindle for

holding and rotating the drill. $he machine is usually hand8fed by means of a rack and

pinion drive on the sleeve holding the rotating spindle. $he machine is driven by vibration

free polyfle@ belts. It is ideal for precision drilling and tapping of light works.

Sa$in Uprig$t Drilling Mac$ine: $his machine is a precision drilling and tapping

machine that is designed to be used in heavier work with respect to the sensitive drilling

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22/38

Machine. It is driven by an adjustably B8belt variator and reduction gearbo@. $he depth

stop can be adjusted. Fi@ automatic drilling feeds for this type enables (uick change of the

tools.

Te!an MAS 567 S 8at$e: $his machine is used to generate forms by removing

material with one single8point cutting tool. It can make several different operations like

drilling reaming boring tapping and grinding by using some accessories and

attachments. $he cutting tool both transverses the a@is of the workpiece revolution and an

angle to that a@is.

0n"t$ Trolc"t 94 C6;94A CNC 8at$e: $his kind of machines are applied in the

industry because of their capabilities for increasing productivity reducing the cost of themachined parts and providing more production fle@ibility. $hey enable faster setups

reduced tool changing re(uirements and increased utili'ation in turn higher productivity.

&igher horse power spindle speeds and feed rates cause faster metal removal rates. $he

availability of more tools minimi'es tool changing re(uirements and often reduces or

eliminates the need for preliminary or secondary operations. Hreater accuracy

repeatability and reliability of the machine has improved the (uality of the parts produced.

.ri&geport


23/38

0n"t$ MFI CNC Milling Mac$ine: $his machine provides controls for two a@es

N #S a@es manual%. It can make drilling tapping milling. It has (uite more accurate results

than the ,ridgeport milling machines.

Uay 44 Sa*ing Mac$ine: It is used for cutting thick materials. It is easy to use

and control. It has wide range of use. $his sawing machine can cut several types of

materials. $he table including the the cutting speed of the machine is given at )ppendi@.

Uay UM-; Sa*ing Mac$ine: It is much smaller than 'ay 33" but it is easy to

use and control. It is used for cutting small plates bars and other small sectioned

materials.

=ero San& .la!ting Mac$ine: $his machine is one of the machines that make

finishing operations in the machineshop. Fand granules are used to clean the surface of

the workpiece. $he surface finishing of all previously machined workpieces is made at that

machine. Cinally these workpieces are send to the (uality check.

Do"%le ,rin&ing Mac$ine: $his machine has two grinding wheels. -ne is used for

rough surfaces. $he other is used for more thin surfaces.

SAMP8E 2OR0PIECES

S"pport Fi>t"re

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24/38

$he support fi@ture is a test fi@ture to hold energy8meter used in &ekos project of

)selsan.

$he material used in production of fi@ture is aluminum. $he first operation cutting

was done in 'ay 33" sawing machine. $hen in ,ridgeport vertical milling machine the

e@ternal boundaries of the fi@ture was machined. )fter this process the workpiece was

sent to the nuth MCI 0 milling machine to machine the inner part of the work. )lso

the fillet of the inner surface was done in nuth 0 milling machine with 21"mm

milling tool. Moreover in nuth 0 milling machine the outer chamfer and the corner

section of the workpiece were machined. Cinally deburring and sand blasting in Sero

sand blasting machine were applied to the surface of the workpiece. )t the end of all

processes the machined fi@ture was sent to the Guality *epartment to ensure that theworkpiece was correctly machined due to the dimensions. )fter (uality check the

support fi@ture was put in production.

Hol&ing Fi>t"re

$he holding fi@ture is again a test fi@ture used in &ekos fi@ture. It is used to hold

the targeting plate of the project.

$he holding fi@ture is made from 3 stainless steel. $he part was again cut in

'ay 33" sawing machine to get the needed section of the steel. $he important

operation of this workpiece was applied in nuth $rolcut 43" /!43) 0 lathe. In this

machine the e@ternal cylindrical surface was obtained. $hen the workpiece was sent to

the Fahin upright drilling machine to machine the internal details. $he hole was drilled in

that machine. )fter this operation the workpiece was sent to the )ciera E$3 precision

tapping machine. $he tap drill was drilled in this machine and also the threads were

opened with M4 tap. Cinally deburring and sand blasting operations were applied to the

fi@ture. )t the end of all these processes the holding fi@ture were sent to the Guality

*epartment. If department will approve the documents of the fi@ture fi@ture will put in

use.

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25/38

A&apter Plate

$he adapter plate is used in the project of II.generation $hermal Hunner Fights. It

is a general8purpose device.

$he material used was )luminum /"/1. Crom a small block of aluminum the

proper part was cut in 'ay 33" sawing machine. $hen the workpiece was sent to the

,ridgeport vertical milling machine to machine the e@ternal part of the fi@ture. )lso in

,ridgeport vertical milling machine the surface was cleaned and the accurate e@ternal

dimensions were obtained. In ,ridgeport milling machine the chamfers were made. )fter

the milling operation the fi@ture was sent to the )ciera 13 $1E sensitive drilling machineto machine the holes. $he 2/mm hole was drilled in that machine. $he ne@t operation

was tapping and this operation was applied in )ciera E$3 precision tapping machine.

Cirst the tap drill was opened and then M1" thread was opened. )gain the workpiece

was sent to the Sero sand blasting machine for cleaning the surface. Cinally the adapter

fi@ture was sent to the Guality *epartment.

.a!e Plate

$he base plate is used to calibrate the MM. $he base plate holds the master

blocks to be measured by the MM.

In the production of the base plate aluminum /"/1 was used. $he first operation

is cutting in 'ay 33" sawing machine. $hen the workpiece was sent to the ,ridgeport

vertical milling machine to obtain the correct thickness and the other e@ternal

dimensions. $he ne@t machine was $e'san M)F 1/5 F lathe. In the $e'san lathe the

cylindrical part was machined with a single point cutting tool. )fter this process

workpiece was again sent to ,ridgeport Bertical milling machine for marking the centers

of the holes. )fter marking plate was sent to Fahin upright drilling machine to open the

21"mm drill to the cylindrical part. $hen the 23.5mm and 2!.5mm drills were opened in

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26/38

)ciera 13 $1E drilling machine. $he last operation was again deburring and sand

blasting in Sero sand blasting machine. Cinally as in all workpieces the base plate was

sent to the Guality *epartment.

8en! Hol&ing Fi>t"re

$he lens holding fi@ture is used in again &ekos project of )selsanTs MHE-

division.

$he )luminum /"/1 block is used in production. $he aluminum block was first cut

in 'ay 33" sawing machine. $hen it was sent to ,ridgeport vertical milling machine to

machine the e@ternal surfaces and the radial details#with 2< drill%. $he workpiece wasmounted to the $e'san M)F 1/5 F lathe. $he outer cylindrical part was machined in that

lathe. )gain in ,ridgeport vertical milling machine the marking of the centers were

applied. $he ne@t machine is Fahin upright drilling machine. In this machine !"mm was

drilled. $hen the fi@ture was sent to the )ciera 13 $1E sensitive drilling machine. $he

/mm and M5 were drilled in this machine. Cinally the finishing operations deburring and

sand blasting were applied to the workpiece. $hen the lens holding fi@ture was sent to

the Guality *epartment.

COST ANA8YSIS OF SAMP8E 2OR0PIECES

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28/38

CONC8USION

$he summer practice program for mechanical engineering has a great

importance for third year students. $he theoretical knowledge of the student is improved

with the practical applications of these learnt in previous lectures. )nother advantage of

ME3"" summer practice program is the relationships between the engineerstechnicians workers and students. $he students become more familiar to the working

ambiance and the working life of the company.

$he first thing learned is the working principles of the company. )lso the duties

and the responsibilities of the engineers in the +roduction Engineering *epartment. $he

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29/38

procedures of design production documentation etc. are easily inspected during this

summer practice program in the company.

$he machineshop of the factory is also useful for me. In this machineshop I saw

the working of some machines. )lso I saw the machining of the workpieces in this

machines. I got detailed informations about the working principles of them. ,y the help

of the technicians I learned the critical parameters of the machines.

In addition to this the production of a workpiece from the selection of the material

to the necessary modifications done from the selection of the machines and cutting tools

to the workers performance from the routings prepared to the (uality controls done and

from the transportation to the marketing.

Moreover during this summer practice program I improved my MF -ffice

knowledge and also I learned a )* program called )uto)* 2814. It is the most widely

used one in the company. )uto)* is used in almost all designs. It is an easy method to

create some complicated drawings.

$he maintenance and production division is a new division for )selsan. ,ecause of

this the machines in machineshop are not so good but enough for small si'ed productions

in the company. $he machines also the 0 machines can be improved in order to

increase the production

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30/38

APPENDI?

8IST OF THE MACHINES

Name o# t$e

mac$ine

N"m%er Name o# t$e

mac$ine

N"m%er

,aykal cuttingmachine

1 'ay 33" sawingmachine

1

,aykal bending

machine

1 ,ridgeport milling

machine

3

)ciera E$3

tapping machine

1 Sero sand

blasting machine

1

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)ciera 13$IE

drilling machine

1 ,aykal spot

welding machine

1

Fahin upright

drilling machine

1 'ay M8!

sawing machine

1

$e'san enginelathe

1

nuth $rolcut

0 lathe

1

nuth MCI 0

milling machine

1

TECHNICA8 INFORMATION OF THE MACHINES

Aciera ET4 Preci!ion Tapping Mac$ine

$apping depth.................................................................!4mm

*iameter of spindle.........................................................1!mm

ollet chuck#shank diameter%............................................/mm

Fpindle speeds....#at 14""rpm motor%........................1!5" rpm

#at !


32/38

*rilling depth................................................."8/"mm #"8!.3/??%

2apid approach stroke.........................!58


33/38

0n"t$ Trolc"t 94 C6;94A CNC 8at$e

Heneral apacity

Fwing over badVVVVVVVVVVVVVVVVV43"mm

Fwing over gapVVVVVVVVVVVVVVVVV//"mm

Fwing over cross slideVVVVVVVVVVVVVV!"mm

*istance between centersVVVVVVVVVVVV1"""mm

Main Fpindle

$ype of spindle noseVVVVVVVVVVVV..*18/ or )18/

Main spindle boreVVVVVVVVVVVVVVVV...5


34/38

,ed widthVVVVVVVVVVVVVVVVVVVV33"mm

,ed heightVVVVVVVVVVVVVVVVVVV.3""mm

+ower

Main drive motorVVVVVVVVVVVVVVVVV5.5kw

oolant pump motorVVVVVVVVVVVVVVVV6"w

;eight and overall dimensions

Cloor dimensionVVVVVVVVVVVVV.!!4"W1"""mm

)ppro@imate weightVVVVVVVVVVVVVVV1/""kg +acking measurementVVVVVVVVVV...#m%!.3W1."W1.5

.ri&geport


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Fpindle speedVVVVVVVVVVVVVVVV!!81

Ceed MotionVVVVVVVVVVVVVVVVV"8/""mmDmin

&igh speed motionVVVVVVVVVVVVVma@. !"""mDmin

+ositioning tolerancesVVVVVVVVVVVVVVV."."4mm

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Motion lengthVVVVVVVVVVVVVVVVV.1"84/mm

Main motor powerVVVVVVVVVVVVVVVVVV!.!kw

*imensions #&W;W%VVVVVVVVVV.!"


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aselsan staj

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