Middle East Technical University[1][1].Son3

8/10/2019 Middle East Technical University[1][1].Son3

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MIDDLE EAST TECHNICAL UNIVERSITY

MECHANICAL ENGINEERING DEPARTMENT

ME300

SUMMER PRACTICE PROGRAM REPORT

Summer 2006

Glba/ANKARA

Prepared by:

mit Emre ERD!AN

"#$2%&'$


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CONTENTS

1) DESCRIPTION OF THE COMPANY(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()

1.1) *+,ati+- +. te +mpa-y1(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((( )1.2) i3t+ry +. te +mpa-y(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((4

1.3) 5ai- Area ab+ut te +mpa-y((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((4

1.4) Number +. Sta.. a-d Di3tributi+- +. E-i-eer3((((((((((((((((((((((((((((((((((((((((((("0

1.5) 7u-,ti+-3 +. 5e,a-i,al E-i-eer3 i- te +mpa-y(((((((((((((((((((((((((((((((((""

1.6) 8i3i+- 9 5i33i+- +. Glerma;((((((((((((((((((((((((((((((((((((((((((((((1((((((((((((((((((("2

1.7)


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4.2) 7+rmi- perati+-311111111111111111111((11(((%0

4.2.1) Fe-di-111111111((((111111111((11111(%0

4.2.1.1)A-le Fe-di-111((111111111((((((((((1111(%"

4.3) +i-i- Pr+,e33e31111111111111111((((1(((((((((((((((((((((((%2

4.3.1) Heldi-11111111111111111((((111111(((%2

4.3.1.1) y.uel Ga3 Heldi-111111111((((((((((((((((((((((((((((%2

4.3.1.2)Ar, Heldi-1111111111111((111(((((((((((((((%2

4.3.1.2.1) Sielded 5etal Ar, Heldi- ?S5AH(((((((11111((%#

4.3.1.2.2) Ga3 u-3te- Ar, Heldi- ?GAH@11(((((((((((((((((((((%#

4.3.1.2.3) Ga3 5etal Ar, Heldi- ?G5AH@(((((((((((((((((((((((((((((((((%#

4.4) Sur.a,e reatme-t a-d 7i-i3i- Pr+,e33e311((((((((((11111(11(%)

4.4.1) Sa-d Fla3ti-11111111111111111111(11%) 4.4.2) eat reatme-t11111(1111111111111111(%6

4.4.2.1)A--eali- Pr+,e33 1111111111111((((((((((((((((%4

5) COMPUTERNUMERICAL CONTROL111111111111111(((111%&

6) OPERATION SE!UENCES OF SOME PARTS1111111111(1111(((%$

6.1) 7la((((((((( ((((((((((((((((((((((((((((((1111111111(11(((((((((((((((((((((((((%$

6.2)B'beam((((((((((((((((((((((((111111111111111(((((((((((((((((((((((((((%$

6.3) Helded plat.+rm((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()0

6.4)+i-t part((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((()0

6.5) +mbi-ed B beam plat.+rm((((1111111111111111111()0

7) COST ANALYSIS OF T%O CHOSEN PARTS111111111111111((()"

7.1) B beam111111111111((((((((((111((((((((((((((((1111111()"

7.2) 7la((((((((((((((((((((((((( 1((((((((((111(1111111111111111()"

8) CONCLUSION 11111111111111111111111111(((1((((()#

APPENDI& A' CHARTS

Pla-t ra-iati+-


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APPENDI& C' T,/*# E-,*+ L+ G,-#9

APPENDI& D' P/:# #*; /,-# ,+, +/, S+


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1. DESCRIPTION OF THE COMPANY

1.1. L#+* +/, C-#*:

COMPANY Glerma; ea>y B-du3trie3 +-3tru,ti+-9

,+-tra,ti+- +( B-,(

LOCATIONK+-ya i'Cay 2#rd ;m(

Glba/IRKEJ

TEL ?#"2@ %&%'2%40

)


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G@LERMA GBL(AI PLANT

e mai- .a,t+ry +. G*ER5AK i3 3ettled +- a- area +. )2000 m2 at te Glba +-

te A-;ara' K+-ya i Cay( e t+tal ,l+3ed area i3 ar+u-d "%000 m2= Ci, ma;e3

er +-e +. te lare3t 3tru,tural a-d me,a-i,al 3teel .abri,ati+- a-d pre33uri3ed>e33el3 ma-u.a,turer i- ur;ey= t+eter Cit a 2000 m2 +. admi-i3trati+- buildi-= a 20

m2)0m buildi- a-d % Ea, 20m&0m buildi-3( All ba3eme-t i3 rei-.+r,ed ,+-,rete(

All ma-u.a,turi- C+r; 3+p3 are eLuipped Cit te p+Cer +utlet3= +t air e-erat+r3

a-d ,+mpre33ed air li-e3( e .a,ility ,+-3i3t3 +. all -e,e33ary eLuipme-t a-d .a,ilitie3

reLuired .+r i Luality a-d e..e,ti>e 3tru,tural 3teel ma-u.a,turi- a-d bear3 maM+r

Luality ,erti.i,ate3 li;e BS $00"= A


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S,, A A,*; ('Plant Settlement plan

1.2. H+: +/, C-#*:

Glerma; i3 te ete-3i+- +. te pri>ate ,+mpa-y .+rmed by 8ilda- Glery u-der i3+C- -ame i- "$)&( i3 pri>ate .irm Ca3 i->+l>ed i- -umer+u3 ,i>il a-d i-du3trial

pr+Me,t3= tur-;ey i-du3trial pla-t3= dam3= iCay3= termal p+Cer pla-t3= r+tary ;il-3

a-d +ter3( B- "$46= Glerma; Ca3 .+rmed a3 a M+i-t 3t+,; ,+rp+rati+-= ta;i- +>er te

eritae +. 8ilda- Glery a-d ,+-ti-ui- al+- te 3ame uideli-e3 u-til t+day(

B- er %4 year3 i- te i-du3try a-d ,+-3tru,ti+- .ield= Glerma; a3 ,+mpleted a lare

am+u-t +. pr+Me,t3 i- >ari+u3 .ield3= Ci, Cere i-di>idually a mile3t+-e i- tede>el+pme-t +. ur;ey( Seydi3eir Alumi-um Pla-t= Ci, i3 te .ir3t a-d +-ly i-terated

alumi-um pla-t i- ur;ey= B3;e-deru- Steel 5ill= Ci, i3 te lare3t i-terated 3teel mill

i- ur;ey i-di>idually deli>eri- Q #0 +. 3teel pr+du,ti+- +. te ,+u-try= %#%0 5H A.i-

' Elbi3ta- ermal P+Cer Pla-t= Ci, i3 te ie3t ,apa,ity li-ite .ired termal p+Cer

pla-t i- ur;ey= B3ta-bul F+3p+ru3 Fride +--e,ti+- 5+t+rCay3= ur;i3 F+ttle 9

Gla33 B-du3trie3 B-,( +(7l+at Gla33 *i-e3 # a-d %=3ta-bul *it Rail 5etr+ Sy3tem

i-,ludi- ele,tr+me,a-i,al C+r;3 a3 Cell a3 te ,i>il C+r;3= are a .eC eample3 +.

te3e pr+Me,t3( Glerma; a3 ,+'+perated Cit ma-y i-ter-ati+-ally re,+-ied .+rei-

,+mpa-ie3 3u, a3 Fu,;au'Halter= AEG= Sieme-3= 8+e3t'Alpi-e= 5it3ubi3i= PF=

Krupp'P+ly3iu3= K+mat3u= A5E Gr+up ?5+r3e Die3el@= e,-ip= Al3t+m= Fab,+,;

F+r3i P+Cer = AFF= A-3ald+= i- retur- re,ei>i- utm+3t appre,iati+- a-d ratitude .r+m

tem .+r te 3uperb C+r; ,+mpleted a3 a M+i-t >e-ture( e m+3t re,e-t illu3trati+- +.

ti3 eperie-,e i3 A*FA +;e al,i-i- Pla-t i- Farai-= ,+mpleted 3u,,e33.ully i- a

>ery 3+rt peri+d(

1.3. M#* A,# #$+ +/, C-#*:

Glerma; i3 -+C C+r;i- +- te part3 +. m+t+r= reda,t+r ,a33i3= ,ir,ular ble-di- bed

a-d al3+ ma-u.a,turi- a-d a33embly +. p+Cer b+iler3 a-d pre33ure >e33el3 i- Glba

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pla-t( He- B parti,ipate i- pr+du,ti+-= te .a,t+ry +perate3 .+urt mai- pr+Me,t3 at te

3ame time( 7ir3t +. te3e C+r;3 i3 me,a-i,al eLuipme-t +. Arabia- eme-t +mpa-y

?A@(e C+r;3+p i3 ma-u.a,turi- ea>y i-du3trial me,a-i,al part3 +. ti3 ,eme-t

,+mpa-y a-d 3e-di- tem t+ Saudi Arabia- eme-t Site by maritime li-e a-d iCay(

Se,+-dly= B3ta-bul SubCay +-3tru,ti+- ?- 3ite@ i3 ,+mpletely ta;e- +- 3ite by

Glerma; a-d 3+me me,a-i,al eLuipme-t 3u, a3 per3+--el tra-3p+rter= beam

3eme-t i3 pr+du,ed i- Glba pla-t( ird +. te3e C+r;3 i3 per.+rmed Cit I-ited

eme-t +rp+rati+- ?I@( ,+->ey+r belt r++m= .a,e ra;er 3y3tem= ,ai- 3,raper=

bride irder= tra>el ,arriae= e-eral eLuipme-t= tie r+d3= dri>e u-it3= .l+ati- beari-=

.ied beari-= bedplate .ied r+ller= bedplate aial ;il- tru3t 3y3tem= bedplate=

a,,e33+rie3 irt ear= 3teel part3 ;il- ++d= Cear ri-= i-let 3eali- +. te Suleyma-

,eme-t .a,t+ry are ma-u.a,tured i- Glba( Detailed table related t+ te3e part3 i3i>e- i- Appe-di( 7i-ally bi+'eta-+l ta-;3 .+r umra 3uar pla-t ?+- 3ite@ are bei-

ma-u.a,tured i- ti3 pla-t a-d Cill 3e-d t+ umra(

C*,:'

A3 early a3 te 40T3= Glerma; 3tarted er l+- 3ta-di- eperie-,e Cit te tur-;ey

pr+du,ti+- +. ,+->ey+r i-3tallati+-3( B- er Glba pla-t= Glerma; i3 able t+ ma-u.a,ture

,+->ey+r r+ller idler3 t+ te late3t DBN 3ta-dard3= t+ te 3tri,te3t a,,ura,y reLuireme-t3(

e3e are ma-u.a,tured >ia 3pe,ial pr+du,ti+- li-e3= Ci, are te +-ly ei3ti- li-e3 +.

teir ;i-d i- ur;ey( Si-,e er 3tart i- ti3 i-du3try u-til t+day= Glerma; a3 ma-u.a,tured

a-d deli>ered ,+u-tle33 ,+->ey+r 3y3tem3 .+r te tra-3p+rtati+- +. material3 3u, a3 ,+al=

ir+- +re= p+3pate= rai-= br+;e- la33 a-d ma-y +ter3( Se i3 te leader i- ti3 i-du3try

i- ur;ey(

C#*, #*; V$#+: R,'

Glerma; a3 a l+- 3ta-di- eperie-,e Cit ydrauli,3 a-d ma,i-ery Cere 3e applie3

ti3 ;-+Clede i- te tele3,+pi, b++m ydrauli, m+bile ,ra-e3= p+rtal ,ra-e3= +>eread

,ra-e3 a-d r+ad ma,i-ery ,+-3tru,ti+-3 .ield3( Hiti- ti3 3,+pe= 3e deli>ered "6 u-it3 "0

&


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t+- m+bile ,ra-e3 a-d )0 u-it3 "=) t+- >ibrat+ry ta-dem r+ller3 t+ te Ge-eral Dire,t+rate +.

iCay3= i- te re,e-t time3(

Sta-dard pr+du,t3 tat a>e bee- .i-i3ed by larma; are

"( ur;i3 ele,tri,ity aut+rity= '42) type= 2) t+- tele3,+pi, b++m m+bile ,ra-e

.abri,ati+- ?"$&"'"$@

2( ur;i3 ele,tri,ity aut+rity= ") t+- tele3,+pi, b++m m+bile ,ra-e .abri,ati+- ?"$&2@

#( ur;i3 ,+al e-terpri3e3 i-,( +(= dump'b+die3 .+r &) t+- eu,lid tru,;3 ?"$&2'"$&%@

%( ur;i3 ,+al e-terpri3e3 i-,( +(= dump'b+die3 .+r &) t+- ;+mat3u tru,;3 ?"$&"'&%@

)( ur;i3 ,+al e-terpri3e3 i-,( +(= dump'b+die3 .+r &) t+- ;+mat3u tru,;3 ?"$&2'&%@

6(Etiba-; e-eral dire,t+rate= eu,lid r'2) ea>y duty tru,; dump b+dy .abri,ati+- ?"$&%@

4( Ge-eral dire,t+rate +. iCay3= "0 u-it3 +. "0 t+- m+bile ,ra-e3 .abri,ati+-?"$$0'

$"@

&( Ge-eral dire,t+rate +. iCay3= )0 u-it3 +. "=) t+- ta-dem >ibrat+ry r+ller ?"$$0'"$$"@

1.4. N-$, S+# #*; D+$+* E*?*,,

$


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ENGINEER NUM(ER DUTY

5e,a-i,al E-i-eer 5

airma-

Ge-eral 5a-aer

Pla-t 5a-aer

e,-i,alDepartme-t ie.

5e,a-i,al

Pr+du,ti+- ie.

i>il E-i-eer3

RE'DE 5a-aer

Pr+Me,t 5a-aer

..er Preparati+-

E-i-eer

5etalluri,al 9 5aterial

E-i-eer 1


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12/53

Fe,+me irre-+u-,able C+r; part-er i- ur;ey a-d rei+- by ,reati- te m+3t

,+->e-ie-t pr+du,t3 a-d 3er>i,e3 .+r ,u3t+mer3 i- ,+-3tru,ti+- 3e,t+r(

M*

Glerma;T3 mi33i+- i3 tat de3i- a-d pr+du,ti+- +. te m+3t ,+->e-ie-t ,+-3tru,ti+-

ma,i-e3 .+r ,u3t+mer3 Cill be d+-e Cit de>+ti+- t+ te pri-,iple3 bel+C:

Parti,ipati>e a-d ,u3t+mer .+,u3ed appr+a,

l+3e part-er3ip Cit pr+,urer3

7leible ma-u.a,turi- a-d team C+r;

Edu,ated C+r; p+Cer a-d u3i- .+rCard te,-+l+y

E..i,ie-,y a-d l+C ,+3t tareted pr+re33i+- ba3i3 ma-aeme-t

Empl+yee plea3ure

Se-3iti>ity t+ 3+,iety a-d e->ir+-me-t

1.7. !#+: P: +/, C-#*:

G*ER5AK3 e

B-,ludi- +. te ,+mmitme-t t+ ,+mply Cit te term3 +. te e-e33=

+ per.+rm te .u-,ti+- +. .rame .+r te ,+-3tituti+- a-d re>ieC +. te Luality

+bMe,ti>e3=

e .+ll+Ci- ide te .+re+i- i33ue3:

"2


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B- +rder t+ ,+->ey te e tem u-der3t++d by te empl+yee3= t+ 3pread +ut te ari+u3 met+d3( e3e met+d3 mit be a3 .+ll+C3:

+ publi3 a-d impleme-t te d+,ume-t3 +. te ide trai-i- =

+ +ld meeti-3 =

+ prepare a--+u-,eme-t3

+ u3e i-ter ,+mmu-i,ati+- 5ea-3

e +p admi-i3trati+- +. G*ER5AK re>ieC3 te i3i+- Ce- it i3 reLuired(

S,, # +/, A,*; A' Glermak Quality Control and Quality Management Flow

Chart

1.8. H,#+/ S#,+: #*; E**-,*+ =HSE) P:

Bt i3 primary +bM,ti>e t+ e-3ure tat Glerma;T3 +perati+-3 pr+>ide 3er>i,e3 i- ealty

a-d 3a.e C+r;i- e->ir+-me-t t+ H+rld 3ta-dart3(

B- ti3 ,+-te= Glerma;T3 primary pri-,iple3 ,+-,er-i- SE are te .+ll+Ci-

U*eal reLuireme-t3 3all 3tri,tly be +b3er>ed i- all +. Glerma;T3 pla,e3 +. C+r;

U Glerma;T3 empl+yee3 at all te e,el+-3 3all be trai-ed u-der SE ma-aeme-t

3y3tem Ci, a3 bee- e3tabli3ed a-d tCy 3all a>e aCare-e33 ab+ut te laC3 a-d

reulati+-3 ,+-,er-i- lab+r ealt= lab+r 3a.ty a-d e->ir+-me-t a-d te 3y3tem 3all

be .urter de>el+ped Cit parti,ipati+- +. all te 3ta.. by ;eepi- up Cit rele>a-t

ad>a-,e3

"#


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UBmpa,t +. Glerma;T3 pr+du,t a-d a,ti>itie3 +- te e->ir+-me-t 3all be mi-imied a-d

Glerma;T3 empl+yee3 3all a>e i-,rea3ed aCare-e33 ab+ut te i33ue +. e->ir+-me-t

i-.+rmati+- 3all be pr+>ided t+ Glerma;T3 ,u3t+mer3= 3upplier3 a-d empl+yee3 +- te

a,ti>itie3 ,+-du,ted t+ pre3er>e te e->ir+-me-t

UGlerma; plede t+ ma;e a>ailable -e,e33ary re3+ur,e3 .+r pr+>i3i+- +. a eatier a-d

3a.er e->ir+-me-t by re>i3i- te e-tire 3y3tem at te ma-aeme-t le>el .+r

3u3tai-ability a-d .urter de>el+pme-t +. a- SE 3y3tem ,+mpatible Cit +ter

,+mpa-y p+li,ie3 Glerma; a>e e3tabli3ed(

1.. O?#*#+*# S++, +/, C-#*:

Superi+r 5a-aeme-t i- Glerma; E3tabli3me-t i3 Ee,uti>e +mmittee( +mmitteedetermi-e3 te ma-aeme-t 3tratey +. te ,+mpa-y a-d a3 rit t+ i33ui- te

e-eral +rder +. te ,+mpa-y= t+ per.+rm te ma-aeme-t +. ++d3 a-d p+>ertie3= a-d

per.+rm all ;i-d3 +. leal C+r;3 bei- i- 3ubMe,t +. te ,+mpa-y i- te -ame +.

,+mpa-y(

Superi+r 5a-aeme-t= i- +rder t+ impr+>e ,+-ti-u+u3ly= re>ieC3 te e-eral ,+-diti+- +.

te ,+mpa-y= Ceter taret3 determi-ed i- pre>i+u3 year are rea,ed +r -+t= a-d te

rea3+-3 +. tem by meeti- +-,e i- a year a-d determi-e3 te taret3 t+ be rea,ed .+r

-et year by rea,i- a de,i3i+- +- ,a-e3 a-d mea3ure3 reLuired t+ be ta;e-(

Ee,uti>e +mmittee determi-e3 te aut+ritie3 a-d re3p+-3ibilitie3 +. te per3+--el

C+ Cill u3e a part +. i3 aut+ritie3 i- te -ame +. im3el.( Ee,uti>e +mmittee ,a-

i>e te repre3e-tati+- duty +. im3el. t+ airma- +. Ee,uti>e +mmittee(

All Glerma; Empl+yee3 a>e all aut+ritie3 a-d re3p+-3ibilitie3 reLuired t+ per.+rm te

dutie3( -e per3+- ,a- be a33i-ed t+ m+re ta- +-e title bei- i- +ra-iati+-

diaram(

"%


15/53

A per3+--el a33i-ed t+ title3 3+C- i- b+ i- +ra-iati+- diaram i3 e>aluated a3

dire,t+r( Dire,t+r i3 re3p+-3ible .+r i3 a..iliated per3+--el t+ C+r; i- a,,+rda-,e Cit

teir duty de.i-iti+-3(

He- de,ided t+ empl+y -eC per3+--el= 3aid per3+--el 3+uld a>e te reLuired

Luali.i,ati+-3( . Ceter te per3+--el a>e te3e Luali.i,ati+-3 are e>aluated by

rele>a-t dire,t+r( All dire,t+r3 i-.+rm te airma- +. Ee,uti>e +mmittee +. te

per3+--el tey -eeded( airma- +. Ee,uti>e +mmittee 3tart3 te -eC per3+--el

empl+yme-t pr+,e33 .+r te +-e3 e .i-d3 a,,eptable .r+m te3e reLue3t3( -e +. te

-eC3paper ad>erti3eme-t3= 3pe,ial uma- 3+ur,e3 ,+mpa-ie3= re,ei>ed appli,ati+-3 +r

3ue3ti+-3 may be applied .+r per3+--el empl+yme-t( Appli,ati+-3 made tr+u

>ari+u3 ,a--el3 are e>aluated by airma- +. Ee,uti>e +mmittee +r rele>a-tdire,t+r a-d m+3t appr+priate ,a-didate i3 empl+yed(

Duty de.i-iti+- +. te duty Ci, e Cill per.+rm i3 eplai-ed t+ all -eC empl+yed

per3+--el a-d i3 3i-ature i3 ta;e- +- ba,; +. rele>a-t 3e,ti+- pae= Ci, e Cill

C+r; .+r i3 title(

S,, # A,*; A' organization chart of Glermak

")


16/53

2. INTRODUCTION

B- me,a-i,al e-i-eeri- departme-t= 3tude-t3 +t 3+me te+reti,al a-d pra,ti,al

;-+Clede ab+ut e-i-eeri- draCi- a-d pr+du,ti+- te,-iLue3 .r+m te ,+ur3e3 5E

""#= 5E ""%= 5E 200 a-d 5E 202 Ci, are i>e- i- te .ir3t a-d 3e,+-d year3(

+Ce>er= pra,ti,al >alue3 a-d ;-+Clede are 3till i-3u..i,ie-t .+r a me,a-i,al e-i-eer

i- te3e ,+ur3e3( B- me,a-i,al e-i-eeri-= te ma-u.a,turi- te,-+l+ie3 a>e a-

imp+rta-t r+le( S+= i- +rder t+ impr+>e te ma-u.a,turi- te,-+l+y ;-+Clede a-dpra,ti,al ability= atte-di- a 3ummer pra,ti,e pr+ram i3 be-e.i,ial .+r me,a-i,al

e-i-eeri- 3tude-t3(

5E #00 3ummer pra,ti,e pr+ram i3 ba3ed +- te pr+du,ti+- te,-iLue3 u3ed a-d it i3

reLuired t+ ma;e +b3er>ati+-3 ab+ut te pr+,e33e3 ,arried +ut i- te ,+mpa-y( e

3tude-t3 put teir te+reti,al >alue3 lear-ed i- pre>i+u3ly ta;e- ,+ur3e3 i-t+ pra,ti,e by

te elp +. e-i-eer3 a-d te,-i,ia-3 C+ are re3p+-3ible .r+m te pr+,e33e3 i- te

+ra-iati+-( i3 impr+>e3 te pr+.e33i+-al ;-+Clede= ability a-d bea>i+r3 +. te

3tude-t3( Bt i3 al3+ u3e.ul .+r adaptati+- t+ pr+.e33i+-al li.e a-d real pr+du,ti+-

te,-iLue3( e 3ummer pra,ti,e pr+ram i3 mu, m+re u3e.ul .+r +b3er>i- >ery

di..ere-t te,-iLue3( Stude-t3 ,a- lear- di..ere-t 3y3tem3 a-d teir C+r;i- pri-,iple3

m+re ea3ily at te 3ame time(

Summer pra,ti,e pr+ram i3 really >ery ++d eperie-,e .+r me,a-i,al e-i-eer

,a-didate3( Stude-t3 3+uld u3e all teir ;-+Clede tey lear-ed .r+m pre>i+u3ly ta;e-

,+ur3e3( Al3+= duri- te 3ummer pra,ti,e te 3tude-t3 ea3ily et a-3Cer3 t+ teir

pr+blem3 a-d Lue3ti+-3 ab+ut te detail3 +. te pr+,e33e3(

"6


17/53

3. MANUFACTURING STEPS

3.1. I*+ +/, F#+:

Pr+.ile material3

Steel Plate3

a3ti- material3

Steel pipe3 5a,i-e pr+du,ti+- 3teel(

S,, # A,*; E' Physical and chemical properties of the St-! "S#$% materials

that are generally used in Glermak

3.2. P,,

utti-

Drilli-

ur-i-

5illi-

Pre33i-

Heldi-

Fe-di-

Gri-di-

eat reatme-t

S+t'Fla3ti-

"4


18/53

PROCESS MACHINING

late3milli- ,utteri-,li-e mule

b+rCer;?b+ri- ma,i-e@driller ri-di- ma,i-eSaC ri-di- ma,i-e

PROCESS DRILLING

radial drilli- ma,i-eaut+mati, pr+.ile driller

N ,utti-'drilli- ma,i-eHa-er drilli- ma,i-e

PROCESS SHOT


19/53

,yli-der

PROCESS THREAD CUTTING

tread ,utti- ma,i-e

PROCESS %ELDING

Ga3 5etal B-ert Heldi-Submered Heldi- 5a,i-e

B->erter Heldi- 5a,i-e

3.3. P;+* F>

7ir3tly= te,-i,al draCi-3 +. C+r; bei- made are draC- +r a>e it br+ut .r+m

a33+,iate ,+mpa-y t+ te,-i,al draCi- +..i,e i- te pla-t( B- ere= C+r; preparati+-

3eet3 are .+rmed Aut+'AD 200% draCi- ,+mputer ba3ed pr+ram( H+r; preparati+-

,+-3i3t dutie3 bei- per.+rmed i- ea, pr+du,ti+- u-it 3eparately( DraCi- paper3 are

i>e- t+ pre'ma-u.a,turi- ,ie.( At te 3ame time Luality ,+-tr+l ma-aeme-t i3

i-.+rmed ab+ut te pr+Me,t( Hit appr+>al +. Luality ma-aeme-t ma-aer= pr+Me,t3 3tart

i- Glerma;(

Pre'ma-u.a,turi- ,ie. determi-e3 te -e,e33ary material3 a-d i-.+rm3 Care+u3e

+..i,ial ,ie. ab+ut tem( At te 3ame time= te3e i-put3 +. te pla-t Ci, are u3ed i-

te ,ertai- pr+Me,t are te3ted i- Luality a33ura-,e departme-t( Fa3i,ally= all material3 are

i-3pe,ted a.ter ea, pr+du,ti+- u-it by Luality ma-aeme-t 3y3tem( Hare+u3e ,ie.

"$


20/53

.+u-d3 reLuired material3 a-d i>e3 tem pre'3a-d bla3ti- part +. te pla-t( A-d te-

te3e material3 are ta;e- pre'ma-u.a,turi- ,ie. re3p+-3ibility( utti- a-d drilli-

pr+,e33e3 are made i- te3e N a-d N ba3ed ma,i-e3( Fe3ide3 radial drilli-

ma,i-e3= K8# 3aC3= ba-d 3aC3= +pti,al 3eari- plate ma,i-e are u3ed depe-di-

+- material3 ,ara,teri3ti,3 a-d ma,i-i- pr+pertie3 a-d 3e-3iti>ity( Additi+-ally= ie.

di>ide3 a-d di3tribute3 material3 i- 3are3 am+- C+r;be-,e3 ta;i- i-t+ teir

a,ti>itie3( B Cill i>e detailed i-.+rmati+- ab+ut ea, pr+,e33 a-d ea, pr+perty +. te3e

ma,i-e3 later +-( Seared a-d drilled material3 are mar;ed te3e ,utti- a-d drilli-

C+r;be-,( 5ar;i- ,+-3i3t3 +. pr+Me,t -umber= p+3e -umber a-d .+rema- -ame tat

Cill ta;e te material3 a-d a33emble Cit i3 team( Fe3ide3 ri-di- pr+,e33 a3 a part

i- pre'ma-u.a,ture +le be,au3e +. rem+>i- burr +- te 3teel plate +r .i- +- a ,a3ti-

material ,au3i- +. ,utti- a-d drilli- pr+,e33(

Pla-t ma-aer di3tribute3 te duty t+ appr+priate team3 Cit re3pe,t t+ teir

Luali.i,ati+-3( A.ter te3e pr+,e33e3= mar;ed C+r; pie,e3 are bei- di3tributed t+ area

+. ea, .+rema- team( 5a-u.a,turi- ,ie. -+C ta;e3 te re3p+-3ibility +. te C+r; .r+m

pre'ma-u.a,turer( e Cat,e3 ,l+3ely te pr+du,t3 a-d teir pr+,e33e3( A3 3ee- ab+>e

tat ra-iati+-al 3tru,ture +. ti3 pr+,edure i3 Luite ierar,i,al(

B- ma-u.a,turi- +le3= tere are "6 team a-d teir Celdi- u-it3( a;e- material3 are

pre'a33embled by ea, team( A-d te- Luality ,+-tr+l ma-aeme-t ,+-tr+l3 ea, ti3

pre'a33embled u-it( Ne,e33ary mea3ureme-t3 a-d +b3er>ati+-3 are d+-e by Luality

,+-tr+ller3 C+ C+r; b+t i- te -ame +. Glerma; a-d ++perati+- +mpa-y(

+-tr+lled C+r; pie,e a33embled Cit >ari+u3 Celdi- te,-iLue3 bei- me-ti+-ed later

+-( Al3+ B Cill me-ti+- ab+ut te ,+-tr+l te,-iLue3 +. Celded material3 u-der teir +C-

title( Gri-di-= Celdi-= a--eali-= a33embli-= 3+me drilli- a-d ,utti- +perati+-3 +

+- i- te3e +le3(

7i-ally= ma-u.a,tured part3 +. 3+me ,eme-t .a,t+ry +r me,a-i,al eLuipme-t3 +. te

,+-3tru,ti+- area i>e- te 3a-d bla3ti- ma,i-e e-erally( B. te pr+du,t dime-3i+-3

are mu, ier ta- ma,i-e= it i3 3ubMe,ted t+ a-d 3a-d'bla3ti- pr+,e33( Smaller +r

20


21/53

te 3ame 3ie 3peri,al 3teel rai-3 are u3ed i- .i-al 3+t'bla3ti- ,+rre3p+-di- Cit

pre'3a-d bla3ti- pr+,e33( S+me err+r3 +. te material appear a.ter bla3ti-( Furr3 a-d

.i-3 +. te material3 are ,lea-ed a.ter te3e pr+,edure3 by ri-di- a-d emery(

4. PRODUCTION TECHNI!UES USED IN THE ORGANI"ATION

4.1. M#+,# R,-#P,,1

B- material rem+>al pr+,e33e3= a 3arp ,utti- t++l i3 u3ed t+ me,a-i,ally rem+>e

material t+ a,ie>e te de3ired e+metry( i3 pr+,e33 i3 al3+ ,alled ma,i-i-( A3 i- all

15i;ell P( Gr++>er= Fundamentals of Manufacturing& pp( %4)

2"


22/53

+ra-iati+-3= ma,i-i- i3 >ery imp+rta-t ma-u.a,turi- pr+,e33 i- Glerma;= 3i-,e

alm+3t all material3 reLuire ma,i-i- at 3+me 3tae +. teir pr+du,ti+-(

e tree pri-,ipal ma,i-i- pr+,e33e3 are tur-i-= drilli- a-d milli-( e +ter

ma,i-i- +perati+-3 i-,lude 3api-= pla-i-= br+a,i- a-d 3aCi-( e ma,i-i-

pr+,e33e3 u3ed i- te +ra-iati+- are: 3aCi-= reami-= 3api-= ri-di-= milli-=

drilli- a-d related +le ma;i- pr+,e33e3= tur-i-= b+ri- a-d related pr+,e33e3(

5a,i-i- i3 a ma-u.a,turi- pr+,e33 i- Ci, a 3arp ,utti- t++l i3 u3ed t+ ,ut aCay

material t+ lea>e te de3ired part 3ape( e pred+mi-a-t ,utti- a,ti+- i- ma,i-i-

i->+l>e3 3ear de.+rmati+-3 +. te C+r; material t+ .+rm a ,ip a3 te ,ip i3 rem+>ed=

a -eC 3ur.a,e i3 ep+3ed( 5a,i-i- i3 m+3t .reLue-tly applied t+ 3ape metal3(

4.1.1 C++*?

utti- pr+,e33e3 are 3eparated i- di..ere-t type3(

4.1.1.1. P#-# A C++*?2

e pla3ma ar, pr+,e33 a3 alCay3 bee- 3ee- a3 a- alter-ati>e t+ te +y'.uel pr+,e33(

B- ti3 part +. te 3erie3 te pr+,e33 .u-dame-tal3 are de3,ribed Cit empa3i3 bei-

pla,ed +- te +perati- .eature3 a-d te ad>a-tae3 +. te ma-y pr+,e33 >aria-t3(

Process fundamentals

e ba3i, pri-,iple i3 tat te ar, .+rmed betCee- te ele,tr+de a-d te C+r; pie,e i3

,+-3tri,ted by a .i-e b+re= ,+pper -+le( i3 i-,rea3e3 te temperature a-d >el+,ity +.te pla3ma ema-ati- .r+m te -+le( e temperature +. te pla3ma i3 i- e,e33 +. 20

000V a-d te >el+,ity ,a- appr+a, te 3peed +. 3+u-d( He- u3ed .+r ,utti-= te

pla3ma a3 .l+C i3 i-,rea3ed 3+ tat te deeply pe-etrati- pla3ma Met ,ut3 tr+u te

material a-d m+lte- material i3 rem+>ed i- te e..lu pla3ma(

2ttp://CCC(tCi(,+(u;/M#2;/pr+te,ted/ba-dW#/M;)"(tml

22


23/53

e pr+,e33 di..er3 .r+m te +y'.uel pr+,e33 i- tat te pla3ma pr+,e33 +perate3 by

u3i- te ar, t+ melt te metal Cerea3 i- te +y'.uel pr+,e33= te +ye- +idi3e3 te

metal a-d te eat .r+m te e+termi, rea,ti+- melt3 te metal( u3= u-li;e te +y'

.uel pr+,e33= te pla3ma pr+,e33 ,a- be applied t+ ,utti- metal3 Ci, .+rm re.ra,t+ry

+ide3 3u, a3 3tai-le33 3teel= alumi-um= ,a3t ir+- a-d -+-'.err+u3 all+y3(

Power source

e p+Cer 3+ur,e reLuired .+r te pla3ma ar, pr+,e33 mu3t a>e a dr++pi-

,ara,teri3ti, a-d a i >+ltae( Alt+u te +perati- >+ltae t+ 3u3tai- te pla3ma i3

typi,ally )0 t+ 608= te +pe- ,ir,uit >+ltae -eeded t+ i-itiate te ar, ,a- be up t+ %008

D(

- i-itiati+-= te pil+t ar, i3 .+rmed Citi- te b+dy +. te t+r, betCee- te ele,tr+de

a-d te -+le( 7+r ,utti-= te ar, mu3t be tra-3.erred t+ te C+r;pie,e i- te 3+',alled

tra-3.erred ar, m+de( e ele,tr+de a3 a -eati>e p+larity a-d te C+r;pie,e a

p+3iti>e p+larity 3+ tat te maM+rity +. te ar, e-ery ?appr+imately tC+ tird3@ i3 u3ed

.+r ,utti-(

Gas composition

B- te ,+->e-ti+-al 3y3tem u3i- a tu-3te- ele,tr+de= te pla3ma i3 i-ert= .+rmed u3i-

ar+-= +r ar+-'2= +r -itr+e-( +Ce>er= +idii- a3e3= 3u, a3 air +r +ye-= ,a- be

u3ed but te ele,tr+de mu3t be ,+pper Cit a.-ium(

e pla3ma a3 .l+C i3 ,riti,al a-d mu3t be 3et a,,+rdi- t+ te ,urre-t le>el a-d te

-+le b+re diameter( B. te a3 .l+C i3 t++ l+C .+r te ,urre-t le>el= +r te ,urre-t le>el

t++ i .+r te -+le b+re diameter= te ar, Cill brea; d+C- .+rmi- tC+ ar,3 i- 3erie3=

ele,tr+de t+ -+le a-d -+le t+ C+r;pie,e( e e..e,t +. d+uble ar,i- i3 u3ually

,ata3tr+pi, Cit te -+le melti-(

Cut quality

2#


24/53

e Luality +. te pla3ma ,ut ede i3 3imilar t+ tat a,ie>ed Cit te +y'.uel pr+,e33(

+Ce>er= a3 te pla3ma pr+,e33 ,ut3 by melti-= a ,ara,teri3ti, .eature i3 te reater

deree +. melti- t+Card3 te t+p +. te metal re3ulti- i- t+p ede r+u-di-= p++r ede

3Luare-e33 +r a be>el +- te ,ut ede( A3 te3e limitati+-3 are a33+,iated Cit te

deree +. ,+-3tri,ti+- +. te ar,= 3e>eral t+r, de3i-3 are a>ailable t+ impr+>e ar,

,+-3tri,ti+- t+ pr+du,e m+re u-i.+rm eati- at te t+p a-d b+tt+m +. te ,ut(

4.1.1.2 CNC O:al>e3 are reulated a,,+rdi- t+ teir pre33ure( i3pre33ure= ,utti- 3peed a-d -+le table i3 i>e- i- te appe-di N'N ,utti-

ma,i-e3( utti- 3y3tem i3 ,+3e- i- ;i-d +. +ye- +r pla3ma( e -+le3 tat are

3pe,i.i, .+r all ,ut material3 are atta,ed( A.ter ti3 pr+,edure= rele>a-t ,utti- pr+ram

tat i3 u3ed +pe-ed i- te ,+mputer a-d ,utti- pr+,e33 3tart3 .r+m ,+3e- re.ere-,e

p+i-t( i3 pr+ram i3 Critte- by e-i-eer3 i- te di3; a-d i>e- t+ rele>a-t C+r;er3(

i,;-e33 +. te 3eared plate determi-e3 te .lame a-d 3peed +. -+le( B- pla3ma

,utti-= ti--er material ta- )0 mm i3 ,ut by pla3ma( I3i- pla3ma i3 mu, e,+-+mi,

a-d reliable but pla3ma -+le3 a>e ier ,+3t ta- +ye-( 7+r ti3 rea3+-= +-,e ti3

-+le i3 damaed= it i3 ard t+ ,a-e( Hit +ye-= te3e ma,i-e3 ,ut te plate3

Cit ti,;-e33 up t+ 200 mm( r'Ni all+yi-= alumi-um= ,a3t ir+- a-d u ,a- -+t be ,ut

by +ye-/ pr+pa-e a-d pla3ma type +. 3eari- i3 applied .+r ti3 type +. plate3(

4.1.1.3 O+# O:e- t+

rele>a-t C+r;er3 i- di..ere-t t+ di3; i- te N( i3 2 dime-3i+-al patter- are put te

3tati+-ary bla,; table a-d +-e 3e-3+r tat a3 ,apability t+ di3ti-,t Cite a-d bla,;( i3

3e-3+r .+ll+C3 te 3ape +. patter-3= a-d -+le3 ,ut te plate3 a>e te 3ame 3ape(

2%


25/53

e3e ma,i-e3 +lder ta- N ba3ed ma,i-e but it i3 m+re .leible ta- N( A-d it

i3 u3ually u3ed i- m+re ,+mple detail3(

4.1.1.3 S/,#*?3

Seari- i3 te me,a-i,al ,utti- +. material3 Cit+ut te .+rmati+- +. ,ip3 by pla,i-

te 3eet betCee- tC+ ede3 +. te 3eari- t++l3( B. te blade3 are 3trait= te

pr+,e33 i3 ,alled 3eari-= but i. te blade e+metry i3 ,ur>ed= a3 i- te ede3 +.

pu-,e3 a-d die3= te pr+,e33 a>e 3pe,ial -ame3= 3u, a3 bla-;i-= pier,i-= -+t,i-

a-d trimmi-( All +. te3e are ba3i,ally 3eari- +perati+-3(

A 3imple type +. 3eari- pr+,e33 i3 tat te pu-, de3,e-d3 aai-3t te C+r; pie,e

te- te metal i3 .ir3t de.+rmed pla3ti,ally i-t+ te die( Fe,au3e te ,leara-,e betCee-

te tC+ t++l3 i3 +-ly )Q t+ "0Q +. te ti,;-e33 +. te metal bei- ,ut= te de.+rmati+-

i3 ily l+,alied( e pu-, pe-etrate3 i-t+ te metal= te material .l+C3 i-t+ te die=

a-d te +pp+3ite 3ur.a,e bule3 3litly( He- pe-etrati+- rea,e3 ab+ut ")Q t+ 60Q

+. ti,;-e33 +. te metal= te am+u-t depe-di- up+- te material du,tility a-d 3tre-t=

te applied 3tre33 e,eed3 te 3ear 3tre33 a-d te metal 3udde-ly 3ear3 +r rupture3

tr+u te remai-der +. it3 ti,;-e33(

Fe,au3e +. te -+rmal i-+m+e-eitie3 i- a metal a-d te p+33ibility +. -+-'u-i.+rm

,leara-,e betCee- te 3ear blade3= te .i-al 3eari- d+e3 -+t +,,ur u-i.+rmly(

7ra,ture a-d teari- 3tart at te Cea;e3t p+i-t3 a-d pr+,eed pr+re33i>ely a-d

i-termitte-tly t+ te -et 3tr+-er l+,ati+-3( e re3ult i3 a r+u a-d raed 3eared

ede(

B. te pu-, a-d die a>e pr+per ,leara-,e a-d are mai-tai-ed i- ++d ,+-diti+-=

3eared ede3 may be pr+du,ed tat are 3u..i,ie-tly 3m++t t+ u3e Cit+ut .urter.i-i3i-( e Luality +. te 3eared ede ,a- be .urter impr+>ed i. te 3trip 3t+,; i3

,lamped .irmly aai-3t te die .r+m ab+>e= te pu-, a-d die are mai-tai-ed Cit pr+per

,leara-,e a-d ali-me-t= a-d te m+>eme-t +. te pie,e tr+u te die i3 re3trai-ed

3E( Paul DeGarm+= emple Fla,;= a-d R+-ald A( K+3er= Materials and Processes in Manufacturing&pp( %60'%62

2)


26/53

by a- +pp+3i- plu-er +r rubber die ,u3i+- applyi- pre33ure .r+m bel+C te C+r;

pie,e( e3e mea3ure3 ,au3e te 3eari- t+ ta;e pla,e u-i.+rmly ar+u-d te ede

rater ta- ra-d+mly at te Cea;e3t p+i-t3( e maM+r pr+,e33i- parameter3 i-

3eari- are te 3ape a-d material3 .+r te pu-, a-d die= te 3peed +. pu-,i-=

lubri,ati+- a-d te ,leara-,e betCee- te pu-, a-d die(

4.1.1.4. S#>*?4

SaCi- i3 a ba3i, ma,i-i- pr+,e33 i- Ci, ,ip3 are pr+du,ed by a 3u,,e33i+- +.

3mall ,utti- ede3= +r teet= arra-ed i- a -arr+C li-e +- a 3aC bladeO( Ea, t++t

.+rm3 a ,ip pr+re33i>ely a3 it pa33e3 tr+u te C+r; pie,e= a-d te ,ip i3

,+-tai-ed Citi- te 3pa,e betCee- tC+ 3u,,e33i>e teet u-til te3e pa33 .r+m te C+r;(

Fe,au3e 3e,ti+-3 +. ,+-3iderable 3ie ,a- be 3e>ered .r+m te C+r; pie,e Cit te

rem+>al +. +-ly a 3mall am+u-t +. te material i- te .+rm +. ,ip3= 3aCi- i3 te m+3t

e,+-+mi,al +. te ba3i, ma,i-i- pr+,e33e3 Cit re3pe,t t+ te Ca3te +. material a-d

p+Cer ,+-3umpti+-= a-d i- ma-y ,a3e3 Cit re3pe,t t+ lab+r( B- re,e-t year3 >a3t

impr+>eme-t3 a>e bee- made i- 3aC blade3 a-d 3aCi- ma,i-e3= re3ulti- i-

impr+>ed a,,ura,y a-d pre,i3i+- +. te pr+,e33(

Sawing machine in Glermak

ir,ular 3aC a-d ba-d 3aC are bel+-i- t+ ti3 r+up i- Glerma;( e3e 3aC3 ,a-

a>e di..ere-t ;i-d +. ,utti- 3ape( B- te3e C+r;be-,e3= ydrauli,3= air pre33ure a-d

pr+re33 3peed mu3t be arra-ed( Pipe3= B'I beam a-d pr+.ile3 are ,ut t+ de3ired

le-t i- te3e ma,i-e3( Fa-d 3aC3 ,a- ,ut larer material3 ta- ,ir,le 3aC3( B- te

ba-d 3aC3= maimum 620'"000 mm dime-3i+-3 material3 are ,ut= Cere a3 i- te

,ir,ular 3aC ma,i-e maimum %)0')00mm dime-3i+-al material3 are bei- ,ut(

4E( Paul DeGarm+= emple Fla,;= a-d R+-ald A( K+3er= Materials and Processes in Manufacturing&pp( 6&)'6&6

26


27/53

Di3ad>a-tae +. te ba-d 3aC i3 3l+Cer tate ,ir,ular +-e( +ri+-tal ,utti- 3aC

ma,i-e ,ut3 te a-le bra,;et be,au3e +. it3 .a3t a-d reliability(

4.1.2M*?5

5illi- i3 a ma,i-i- +perati+- i- Ci, a C+r;part i3 .ed pa3t a r+tati- ,yli-dri,al t++l

Cit multiple ,utti- ede3 ?i- rare ,a3e3= a t++ Cit +-e ,utti- ede= ,alled a .ly',utter=

i3 u3ed@( e ai3 +. r+tati+- +. te ,utti- t++l i3 perpe-di,ular t+ te dire,ti+- +. .eed(

i3 +rie-tati+- betCee- te t++l ai3 a-d te .ee3 dire,ti+- i3 +-e +. te .eature3 tat

di3ti-ui3 milli- .r+m drilli-( B- drilli-= te ,utti- t++l i3 .ed i- a dire,ti+- parallel t+

it3 ai3 +. r+tati+-( e ,utti- t++l i- milli- i3 ,alled a milli- ,utter a-d te ,utti-

ede3 are ,alled teet( e ma,i-e t++l tat traditi+-ally per.+rm3 ti3 +perati+- i3 a

milli- ma,i-e(

e e+metri, .+rm ,reated by milli- i3 a pla-e 3ur.a,e( ter C+r; e+metrie3 ,a- be

,reated eiter by mea-3 +. te ,utter pat +r te ,utter 3ape( Ci- t+ te >ariety +.

3ape3 p+33ible a-d it3 i pr+du,ti+- rate3= milli- i3 +-e +. te m+3t >er3atile a-d

Cidely u3ed ma,i-i- +perati+-3(

5illi- i3 a- i-terrupted ,utti- +perati+- te teet +. te milli- ,utter e-ter a-d eit te

C+r; duri- ea, re>+luti+-( i3 i-terrupted ,utti- a,ti+- 3ubMe,t3 te teet t+ a ,y,le

+. impa,t .+r,e a-d termal 3+,; +- e>ery r+tati+-( e t++l material a-d ,utter

e+metry mu3t be de3i-ed t+ Cit3ta-d te3e ,+-diti+-3(

T:, -*? ,#+*

ere are tC+ ba3i, type3 +. milli- +perati+-3

a@ periperal milli-

b@ .a,e milli-

P,/,# -*?

55i;ell P( Gr++>er= Fundamentals of Manufacturing& pp( )")')"4

24


28/53

B- periperal milli-= al3+ ,alled plai- milli-= te ai3 +. te t++l i3 parallel t+ te 3ur.a,e

bei- ma,i-ed= a-d te +perati+- i3 per.+rmed by ,utti- ede3 +- te +ut3ide

peripery +. te ,utter(

T:, ,/,# -*?'

S#$ -*?: e ba3i, .+rm +. periperal milli- te ,utter Cidt ete-d3 bey+-d te

C+r;pie,e +- b+t 3ide3(

S++*?: Sl+tti- i3 al3+ ,alled 3l+t milli-( e Cidt +. te ,utter i3 le33 tate

C+r;pie,e Cidt= ,reati- a 3l+t i- te C+r;( He- te ,utter i3 >ery ti-= ti3 +perati+-

,a- be u3ed t+ mill -arr+C 3l+t3 +r ,ut a C+r;part i- tC+= ,alled 3aC milli-(

S;, -*?: e ,utter ma,i-e3 te 3ide +. te C+r;pie,e(

S+#;;, -*?: e 3ame a3 3ide milli-= +-ly ,utti- ta;e3 pla,e +- b+t 3ide3 +. te

C+r;(

B- periperal milli-= te r+tati+- dire,ti+- +. te ,utter di3ti-ui3e3 tC+ .+rm3 +. milli-:

up milli- a-d d+C- milli-( B- up milli-= al3+ ,alled ,+->e-ti+-al milli-= te dire,ti+-

+. m+ti+- +. te ,utter teet i3 +pp+3ite te .eed dire,ti+- Ce- te teet ,ut i-t+ teC+r;( Bt i3 milli- Xaai-3t te .eedT( B- d+C- milli-= al3+ ,alled ,limb milli-= te

dire,ti+- +. ,utter m+ti+- i3 te 3ame a3 te .eed dire,ti+- Ce- te teet ,ut te C+r;(

Bt i3 milli- XCit te .eedT(

e relati>e e+metrie3 +. te3e tC+ .+rm3 +. milli- re3ult i- di..ere-,e3 i- teir ,utti-

a,ti+-3( B- up milli-= te ,ip .+rmed by ea, ,utter t++t 3tart3 +ut >ery ti- a-d

i-,rea3e3 i- ti,;-e33 duri- te 3Ceep +. te ,utter( B- d+C- milli-= ea, ,ip 3tart3

+ut ti,; a-d redu,e3 i- ti,;-e33 tr+u+ut te ,ut( e le-t +. a ,ip i- d+C-milli- i3 le33 ta- i- up milli-( i3 mea-3 tat te ,utter i3 e-aed i- te C+r; .+r

le33 time per >+lume +. material ,ut= a-d ti3 te-d3 t+ i-,rea3e t++l li.e i- d+C- milli-(

e ,utti- .+r,e dire,ti+- i3 ta-e-tial t+ te peripery +. te ,utter .+r te teet tat

are e-aed i- te C+r;( B- up milli-= ti3 a3 a te-de-,y t+ li.t te C+r;part a3 te

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29/53

,utter teet eit te material( B- d+C- milli- ti3 ,utter .+r,e dire,ti+- i3 d+C-Card=

te-di- t+ +ld te C+r; aai-3t te milli- ma,i-e table(

F#, -*?

B- .a,e milli-= te ai3 +. te ,utter i3 perpe-di,ular t+ te 3ur.a,e bei- milled = a-d

ma,i-i- i3 per.+rmed by ,utti- ede3 +- b+t e-d a-d +ut3ide peripery +. te

,utter( A3 i- periperal milli-= >ari+u3 .+rm3 +. .a,e milli- ei3t:

a@ +->e-ti+-al .a,e milli-: e diameter +. te ,utter i3 reater tate

C+r;part Cidt= 3+ tat te ,utter +>era-3 te C+r; +- b+t 3ide3(

b@ Partial .a,e milli-: e ,utter +>era-3 te C+r; +- +-ly +-e 3ide(

,@ E-d milli-: e ,utter diameter i3 le33 tate C+r; Cidt= 3+ a 3l+t i3 ,uti-t+ te part(

d@ Pr+.ile milli-: i3 i3 a .+rm +. e-d milli- i- Ci, te +ut3ide peripery +. a

.lat part i3 ,ut(

e@ P+,;et milli-: P+,;et milli- i3 a-+ter .+rm +. e-d milli-= ti3 i3 u3ed t+ mill

3ad+C p+,;et3 i-t+ te .lat part3(

@ Sur.a,e ,+-t+uri-: A ball'-+3e ,utter i3 .ed ba,; a-d .+rt a,r+33 te C+r;

al+- a ,ur>ili-ear pat at ,l+3e i-ter>al3 t+ ,reate a tree'dime-3i+-al 3ur.a,e .+rm(

e 3ame ba3i, ,utter ,+-tr+l i3 reLuired t+ ma,i-e te ,+-t+ur3 +. m+ld3 a-d die3= i-

Ci, ,a3e +perati+-3 i3 ,alled die 3i-;i-(

4.1.3 T**?6

ur-i- i3 a ma,i-i- pr+,e33 i- Ci, a 3i-le p+i-t t++l rem+>e3 material3 .r+m te

3ur.a,e +. a r+tati- ,yli-dri,al C+r;pie,e te t++l i3 .ed li-early i- a dire,ti+- parallel t+

te ai3 +. r+tati+-( ur-i- i3 traditi+-ally ,arried +ut +- a ma,i-e t++l ,alled a late=

Ci, pr+>ide3 p+Cer t+ tur- te part at a i>e- r+tati+-al 3peed a-d t+ .eed te t++l at

a 3pe,i.ied rate a-d dept +. ,ut(

65i;ell P( Gr++>er= Fundamentals of Manufacturing& pp( )02')0)

2$


30/53

C++*? C*;+* * T**?

e r+tati+-al 3peed i- tur-i- i3 related t+ te de3ired ,utti- 3peed at te 3ur.a,e +.

te ,yli-dri,al C+r;pie,e by te eLuati+-:

R+tati+-al 3peed ?re>/mi-@: N

utti- 3peed ?m/mi-@: >

rii-al diameter ?m@: D+

N Y > / D+

e tur-i- +perati+- redu,e3 te diameter +. te C+r; .r+m D+ t+ .i-al diameter D.( e

,a-e i- diameter i3 determi-ed by te dept +. ,ut d:

D+ Z D. Y 2d

e .eed i- tur-i- i3 e-erally epre33ed i- mm/re>( i3 .eed ,a- be ,+->erted t+ a

li-ear tra>el rate i- mm/mi- by te .+rmula:

.rY N.

Here .r Y .eed rate ?mm/mi-@ a-d . Y .eed ?mm/re>@(

e time t+ ma,i-e .r+m +-e +. a ,yli-dri,al C+r;part t+ te +ter i3 i>e- by

m Y */ .r

Cere m Y time +. a,tual ma,i-i-?mi-ute3@ a-d * Y le-t +. te ,yli-dri,al

C+r;part= mm( A3 a pra,ti,al matter= a 3mall di3ta-,e i3 u3ually added t+ te le-t at

te bei--i- a-d e-d +. te C+r;pie,e t+ all+C .+r appr+a, a-d +>er tra>el +. te t++l(

e >+lumetri, rate +. material rem+>al ,a- be m+3t ,+->e-ie-tly determi-ed by te

.+ll+Ci- eLuati+-:

5RR Y >.d

#0


31/53


32/53

M@ K-urli-: i3 i3 -+t a ma,i-i- +perati+- be,au3e it d+e3 -+t i->+l>e ,utti-

+. material( B-3tead= it i3 a metal .+rmi- +perati+- u3ed t+ pr+du,e a reular

,r+33at,ed patter- i- te C+r; 3ur.a,e(

5+3t late +perati+-3 u3e 3i-le'p+i-t t++l3( ur-i-= .a,i-= taper tur-i-=,+-t+ur tur-i-= ,am.eri-= a-d b+ri- are all per.+rmed Cit 3i-le'p+i-t t++l3( A

treadi- +perati+- i3 a,,+mpli3ed u3i- a 3i-le'p+i-t t++l de3i-ed Cit a e+metry

tat 3aped te tread( ertai- +perati+-3 reLuire t++l3 +ter ta- 3i-le'p+i-t( 7+rm

tur-i- i3 per.+rmed Cit a 3pe,ially de3i-ed t++l ,alled a .+rm t++l( e pr+.ile 3ape

r+u-d i-t+ te t++l e3tabli3e3 te 3ape +. te C+r;part( A ,ut+.. t++l i3 ba3i,ally a

.+rm t++l( Drilli- i3 a,,+mpli3ed by a drill bit( K-urli- i3 per.+rmed by a ;-urli- t++l=

,+-3i3ti- +. tC+ arde-ed .+rmi- r+ll3= ea, m+u-ted betCee- ,e-ter3( e .+rmi-r+ll3 a>e te de3ired ;-urli- patter- +- teir 3ur.a,e3(

Stages of Drilling Operation in a athe

A late ,a- be u3ed t+ drill +le3 a,,urately ,+-,e-tri, Cit te ,e-terli-e +. a

,yli-dri,al part( 7ir3t= a drill ,u,; i3 i-3talled i-t+ te tail3t+,;( Bt mu3t be 3ee- tat tat

te ta- +- te ba,; +. te drill ,u,; 3eat3 pr+perly i- te tail3t+,;( e MaC3 +. te

,u,; are CitdraC- a-d te ,u,; i3 tapped i- pla,e Cit a 3+.t ammer( e 3addle i3

m+>ed .+rCard t+ ma;e r++m .+r te tail3t+,;( e tail3t+,; i3 m+>ed i-t+ p+3iti+-= a-d it

i3 l+,;ed i- pla,e ?+terCi3e it Cill 3lide ba,;Card Cile drilli-@( Fe.+re 3tarti- te

ma,i-e= 3pi-dle i3 tur-ed by a-d( e 3addle i3 m+>ed .+rCard= 3+ it ,+uld i-ter.ere

Cit te r+tati+- +. te late ,u,;( AlCay3 ,e-ter drill mu3t be u3ed t+ 3tart te +le(

utti- .luid 3+uld be u3ed Cit te ,e-ter drill( Bt a3 3all+C .lute3 ?.+r added

3ti..-e33@ a-d d+e3-t ,ut a3 ea3ily a3 a drill bit(

AlCay3 it 3+uld be drilled pa3t te bei--i- +. te taper t+ ,reate a .u--el t+ uide te

bit i-( At m+3t +-e +r tC+ drill diameter3 +. material 3+uld be ta;e- be.+re ba,;i- +..=

,leari- te ,ip3= a-d applyi- ,utti- .luid( B. te drill bit 3Luea;3= 3+l>e-t i3 applied

m+re +.te-( e drill ,u,; ,a- be rem+>ed .r+m te tail3t+,; by draCi- ba,; te drill

#2


33/53

,u,; a3 .ar a3 it Cill ea3ily += te- ab+ut a Luarter tur- m+re( A pi- Cill pre33 te ,u,;

+ut +. te ,+llet(

4.1.4. D*?

Drilli- i3 a ma,i-i- +perati+- u3ed t+ ,reate a r+u-d +le i- a C+r;part( B- ,+-tra3t

Cit b+ri- tat ,a- +-ly be u3ed t+ e-lare a- ei3ti- +le( Drilli- i3 u3ually

per.+rmed Cit a r+tati- ,yli-dri,al t++l Ci, a3 tC+ ,utti- ede3 +- it3 C+r;i- e-d(

e t++l i3 ,alled a drill +r drill bit( e r+tati- drill .eed3 i-t+ te 3tati+-ary C+r;part t+

.+rm a +le C+3e diameter i3 eLual t+ te drill diameter( Drilli- i3 ,u3t+marily

per.+rmed +- a drill pre33= alt+u +ter ma,i-e t++l3 ,a- al3+ per.+rm ti3 +perati+-(

Cutting conditions in drilling

e ,utti- 3peed i- a drilli- +perati+- i3 te 3ur.a,e 3peed at te +ut3ide diameter +.

te drill( Bt i3 3pe,i.ied i- ti3 Cay .+r ,+->e-ie-,e= e>e- t+u -early all +. te ,utti- i3

a,tually per.+rmed at l+Cer 3peed3 ,l+3er t+ te ai3 +. r+tati+-( + 3et te de3ired

,utti- 3peed i- drilli-= it i3 -e,e33ary t+ determi-e te r+tati+-al 3peed +. te drill .+r

it3 diameter( *etti- N repre3e-t3 te 3pi-dle re>/mi-

N Y > / D

Here >Y ,utti- 3peed= mm/mi- a-d D Y te drill diameter= mm( B- 3+me drilli-

+perati+-3= te C+r;pie,e i3 r+tated ab+ut a 3tati+-ary t++l= but te 3ame .+rmula

applie3(

7eed . i- drilli- i3 3pe,i.ied i- mm/re>( Re,+mme-ded .eed3 are r+uly pr+p+rti+-al t+

drill diameter ier .eed3 are u3ed Cit larer diameter drill3( Si-,e tere are tC+

,utti- ede3 at te drill p+i-t= te u-,ut ,ip ti,;-e33 ?,ip l+ad@ ta;e- by ea, ,utti-ede3 i3 al. te .eed( 7eed ,a- be ,+->erted t+ .eed rate u3i- te 3ame eLuati+- a3

.+r tur-i-:

.rY N.

##


34/53

Here .rY .eed rate= mm/mi-(

Drilled +le3 are eiter tr+u +le3 +r bli-d +le3( B- tr+u +le3= te drill eit3 te

+pp+3ite 3ide +. te C+r; i- bli-d +le3= it d+e3 -+t( e ma,i-i- time reLuired t+ drill

a tr+u +le ,a- be determi-ed by te .+ll+Ci- .+rmula(

m Y ?t [ A@/.r

Cere m Y ma,i-i-?drilli-@ time= mi- .rY .eed rate= mm/mi- a-d A Y a-

appr+a, all+Ca-,e tat a,,+u-t3 .+r te drill p+i-t a-le= repre3e-ti- te di3ta-,e te

drill mu3t .eed i-t+ te C+r; be.+re rea,i- .ull diameter( i3 all+Ca-,e i3 i>e- by

AY 0() D ta-?$0'/2)

Cere A Y appr+a, all+Ca-,e= mm a-d \Y\drill p+i-t a-le(

B- a bli-d +le= +le dept d i3 de.i-ed a3 te di3ta-,e .r+m te C+r; 3ur.a,e t+ te

Xp+i-tT +. te +le( Fy ti3 de.i-iti+-= te drill p+i-t a-le all+Ca-,e d+e3 -+t a..e,t te

time t+ drill te +le( u3 .+r a drill +le= ma,i-i- time i3 i>e- by

m Y d/ .r

e rate +. te metal rem+>al i- drilli- i3 determi-ed a3 te pr+du,t +. te drill

,r+33'3e,ti+-al area a-d te .eed rate:

5RR Y \\D2.r/%

i3 eLuati+- i3 >alid +-ly a.ter te drill rea,e3 .ull diameter a-d e,lude3 te i-itial

appr+a, +. te drill i-t+ te C+r;(

O,#+* ,#+,; + ;*?

Se>eral +perati+-3 are related t+ drilli-( 5+3t +. te +perati+-3 .+ll+C drilli- a +le

mu3t be made .ir3t by drilli-= a-d te- te +le i3 m+di.ied by +-e +. te +ter

#%


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+perati+-3( e-teri- a-d 3p+t.a,i- are e,epti+-3 t+ ti3 rule( All +. te +perati+-3

u3e r+tati- t++l3(

a@ Reami-: Reami- i3 u3ed t+ 3litly e-lare a +le= t+ pr+>ide a better

t+lera-,e +- it3 diameter= a-d t+ impr+>e it3 3ur.a,e .i-i3( e t++l i3 ,alled a reamer=a-d it u3ually a3 3trait .lute3(

b@ appi-: i3 +perati+- i3 per.+rmed by a tap a-d i3 u3ed t+ pr+>ide

i-ter-al 3,reC tread3 +- a- ei3ti- +le(

,@ +u-terb+ri-: +u-terb+ri- pr+>ide3 a 3tepped +le= i- Ci, a larer

diameter .+ll+C3 a 3maller diameter partially i-t+ te +le( A ,+u-terb+red +le i3 u3ed

t+ 3eat b+lt ead3 i-t+ a +le 3+ te ead3 d+ -+t pr+du,e ab+>e te 3ur.a,e(

d@ +u-ter3i-;i-: i3 i3 3imilar t+ ,+u-terb+ri-= e,ept tat te 3tep i- te+le i3 ,+-e'3aped .+r .lat ead 3,reC3 a-d b+lt3(

e@ e-teri-: Al3+ ,alled ,e-terdrilli-= ti3 +perati+- drill3 a 3tarti- +le t+

a,,urately e3tabli3 it3 l+,ati+- .+r 3ub3eLue-t drilli-( e t++l i3 ,alled a ,e-terdrilli-(

Sp+t.a,i-: Sp+t.a,i- i3 3imilar t+ milli-( Bt i3 u3ed t+ pr+>ide a .lat ma,i-ed 3ur.a,e

+- te C+r;part i- a l+,alied area(

4.1.5. (*?

7

F+ri- i3 3imilar t+ tur-i-( Bt u3e3 a 3i-le'p+i-t t++l aai-3t a r+tati- C+r;part( e

di..ere-,e i3 tat b+ri- i3 per.+rmed +- te i-3ide diameter +. a- ei3ti- +le rater

tate +ut3ide diameter +. a- ei3ti- ,yli-der( B- e..e,t= b+ri- i3 a- i-ter-al tur-i-

+perati+-( 5a,i-e t++l3 u3ed t+ per.+rm b+ri- +perati+-3 are ,alled b+ri- ma,i-e3(

-e mit e,ept tat b+ri- ma,i-e3 C+uld a>e .eature3 i- ,+mm+- Cit tur-i-

ma,i-e3 i-deed a3 pre>i+u3ly i-di,ated= late3 are 3+metime3 u3ed t+ a,,+mpli3

b+ri-(

4.1.6. G*;*?8

75i;ell P( Gr++>er= Fundamentals of Manufacturing& pp( )0$85i;ell P( Gr++>er= Fundamentals of Manufacturing& pp( )&6')&4= )$4'600

#)


36/53

Gri-di- i3 a material'rem+>al pr+,e33 i- Ci, abra3i>e parti,le3 are ,+-tai-ed i- a

b+-ded ri-di- Ceel tat +perate3 at >ery i 3ur.a,e 3peed3( e ri-di- Ceel i3

u3ually di3;'3aped= a-d i3 pre,i3ely bala-,ed .+r i r+tati+-al 3peed3(

Gri-di- ,a- be li;e-ed t+ te milli- pr+,e33( utti- +,,ur3 +- eiter te peripery +rte .a,e +. te ri-di- Ceel= 3imilar t+ periperal milli- a-d .a,e milli-( Periperal

ri-di- i3 mu, m+re ,+mm+- ta- .a,e ri-di-( e r+tati- ri-di- Ceel ,+-3i3t3

+. ma-y ,utti- teet ?te abra3i>e parti,le3@= a-d te C+r; i3 .ed relati>e t+ te Ceel t+

a,,+mpli3 material rem+>al(

The Grinding !heel

A ri-di- Ceel ,+-3i3t3 +. abra3i>e parti,le3 a-d b+-di- material( e b+-di-material +ld3 te parti,le3 i- pla,e a-d e3tabli3e3 te 3ape a-d 3tru,ture +. te

Ceel( e3e tC+ i-redie-t3= a-d te Cay tey are .abri,ated= determi-e te

parameter3 +. te ri-di- Ceel= Ci, are:

"@ Abra3i>e material

2@ Grai- 3ie

#@ F+-di- material

%@ Heel rade

)@ Heel 3tru,ture

e3e parameter3 are a-al++u3 t+ te material a-d e+metry +. a ,+->e-ti+-al ,utti-

t++l( + a,ie>e te de3ired per.+rma-,e i- a i>e- appli,ati+-= ea, +. te parameter3

mu3t be ,are.ully 3ele,ted(

Grinding Operations and Grinding "achines

Gri-di- i3 traditi+-ally u3ed t+ .i-i3 part3 C+3e e+metrie3 a>e already bee-

,reated by +ter +perati+-3( A,,+rdi-ly= ri-di- ma,i-e3 a>e bee- de>el+ped t+

ri-d plai- .lat 3ur.a,e3= eter-al a-d i-ter-al ,yli-der3 a-d ,+-t+ur 3ape3 3u, a3

tread3( e ,+-t+ur 3ape3 are +.te- ,reated by 3pe,ial .+rmed Ceel3 tat a>e te

+pp+3ite +. te de3ired ,+-t+ur t+ be imparted t+ te C+r;( Gri-di- i3 al3+ u3ed i- t++l

#6


37/53

r++m3 t+ .+rm te e+metrie3 +- ,utti- t++l3( B- additi+- t+ te3e traditi+-al u3e3=

appli,ati+-3 +. ri-di- are epa-di- t+ i-,lude m+re i'material rem+>al +perati+-3(

ur di3,u33i+- +. +perati+-3 a-d ma,i-e3 i- ti3 3e,ti+- i-,lude3 te .+ll+Ci- type3:

"@ 3ur.a,e ri-di-2@ ,yli-dri,al ri-di-

#@ ,e-terle33 ri-di-

%@ ,reep .eed ri-di-

Surface Grinding

Sur.a,e ri-di- i3 -+rmally u3ed t+ ri-d plai- .lat 3ur.a,e3( Bt i3 per.+rmed u3i- eiter

te peripery +. te ri-di- Ceel +r te .lat .a,e +. te Ceel( Si-,e te C+r; i3-+rmally eld i- a +ri+-tal +rie-tati+-= periperal ri-di- i3 per.+rmed by r+tati- te

Ceel ab+ut a +ri+-tal ai3 a-d .a,e ri-di- i3 per.+rmed by r+tati- te Ceel ab+ut

a >erti,al ai3( B- eiter ,a3e= te relati>e m+ti+- +. te C+r;part i3 a,ie>ed by

re,ipr+,ati- te C+r; pa3t te Ceel +r r+tati- it( e3e p+33ible ,+mbi-ati+-3 +.

Ceel +rie-tati+-3 a-d C+r;part m+ti+-3 yield te .+ur type3

. te .+ur type3= te +ri+-tal 3pi-dle ma,i-e Cit re,ipr+,ati- C+r;table i3 te m+3t

,+mm+-( Gri-di- i3 a,,+mpli3ed by re,ipr+,ati- te C+r; l+-itudi-ally u-der te

Ceel at a >ery 3mall dept a-d by .eedi- te Ceel tra-3>er3ely i-t+ te C+r; a

,ertai- di3ta-,e betCee- 3tr+;e3(

B- additi+- t+ it3 ,+->e-ti+-al appli,ati+-= a ri-di- ma,i-e Cit +ri+-tal 3pi-dle a-d

re,ipr+,ati- table ,a- be u3ed t+ .+rm 3pe,ial ,+-t+ured 3ur.a,e3 by empl+yi- a

.+rmed ri-di- Ceel( B-3tead +. .eedi- te Ceel tra-3>er3ely a,r+33 te C+r; a3 it

re,ipr+,ate3= te Ceel i3 plu-e'.ed >erti,ally i-t+ te C+r;( e 3ape +. te .+rmed

Ceel i3 tere.+re imparted t+ te C+r; 3ur.a,e(

Gri-di- ma,i-e3 Cit >erti,al 3pi-dle3 a-d re,ipr+,ati- table3 are 3et up 3+ tat te

Ceel diameter i3 reater tate C+r; Cidt( A,,+rdi-ly= te3e +perati+-3 ,a- be

per.+rmed Cit+ut u3i- a tra-3>er3e .eed m+ti+-( B-3tead= ri-di- i3 a,,+mpli3ed by

#4


38/53

re,ipr+,ati- te C+r; pa3t te Ceel a-d .eedi- te Ceel >erti,ally i-t+ te C+r; t+

te de3ired dime-3i+-( i3 ,+-.iurati+- i3 ,apable +. a,ie>i- >ery .lat 3ur.a,e +- te

C+r;(

. te tC+ type3 +. r+tary table ri-di-= te >erti,al 3pi-dle ma,i-e3 are m+re,+mm+-( Ci- t+ te relati>ely lare 3ur.a,e ,+-ta,t area betCee- Ceel a-d

C+r;part= >erti,al 3pi-dle'r+tary table ri-di- ma,i-e3 are ,apable +. i metal

rem+>al rate3 Ce- eLuipped Cit appr+priate ri-di- Ceel3(

Cylindrical Grinding

A3 it3 -ame 3ue3t3= ,yli-dri,al ri-di- i3 u3ed .+r r+tati+-al part3( e3e ri-di-

+perati+-3 di>ide i-t+ tC+ ba3i, type3:

' Eter-al ,yli-dri,al ri-di-

' B-ter-al ,yli-dri,al ri-di-

Eter-al ,yli-dri,al ri-di- ?al3+ ,alled ,e-ter'type ri-di- t+ di3ti-ui3 it .r+m

,e-terle33 ri-di-@ i3 per.+rmed mu, li;e a tur-i- +perati+-( e ri-di- ma,i-e3

u3ed .+r te3e +perati+-3 ,l+3ely re3emble a late i- Ci, te t++l p+3t a3 bee-

repla,ed by a i 3peed m+t+r t+ r+tate te ri-di- Ceel( ere tC+ type3 +. .eedm+ti+- p+33ible= tra>er3e .eed a-d plu-e',ut( B- tra>er3e .eed= te ri-di- Ceel i3 .ed

i- a dire,ti+- parallel t+ te ai3 +. r+tati+- +. te C+r;part( A l+-itudi-al re,ipr+,ati-

m+ti+- i3 3+metime3 i>e- t+ eiter te C+r; +r te Ceel t+ impr+>e 3ur.a,e .i-i3( B-

plu-e',ut= te ri-di- Ceel i3 .ed radially i-t+ te C+r;(

Eter-al ,yli-dri,al ri-di- i3 u3ed t+ .i-i3 part3 tat a>e bee- ma,i-ed t+

appr+imate 3ie a-d eat treated t+ de3ired ard-e33( Part3 i-,lude ale3= ,ra-;3a.t3=

3pi-dle3= beari-3 a-d bu3i-3 a-d r+ll3 .+r r+lli- mill3( e ri-di- +perati+-

pr+du,e3 te .i-al 3ie a-d reLuired 3ur.a,e .i-i3 +- te3e arde-ed part3(

Centerless Grinding

#&


39/53

e-terle33 ri-di- i3 a- alter-ati>e pr+,e33 .+r ri-di- eter-al a-d i-ter-al ,yli-dri,al

3ur.a,e3( A3 it3 -ame 3ue3t3= te C+r;pie,e i3 -+t eld betCee- ,e-ter3( i3 re3ult3

i- a redu,ti+- i- C+r; a-dli- time e-,e= ,e-terle33 ri-di- i3 +.te- u3ed .+r i

pr+du,ti+- C+r;( e 3etup .+r e#ternal centerless grinding,+-3i3t3 +. tC+ Ceel3

te ri-di- Ceel a-d a reulati- Ceel( e C+r;part3= Ci, may be i-di>idual 3+rt

pie,e3 +r l+- r+d3 are 3upp+rted by a re3t blade a-d .ed tr+u betCee- te tC+

Ceel3( e ri-di- Ceel d+e3 te ,utti-( e reulati- Heel r+tate3 at mu,

l+Cer 3peed3 a-d i3 i-,li-ed at a 3lit a-le t+ ,+-tr+l tr+u .eed +. te C+r;(

4.1.7. P,*? #*; (#*9*?

P,*?

Pier,i- i3 te +perati+- +. ,utti- i-ter-al .eature3 ?+le3 +r 3l+t3@ i- 3t+,;( Pier,i- ,a-

al3+ be ,+mbi-ed Cit +ter +perati+-3 3u, a3 la-,e a-d .+rm ?t+ ma;e a 3mall .eature

3u, a3 tab@= pier,e a-d etrude ?t+ ma;e a- etruded +le@( All te3e +perati+-3 ,a- be

,+mbi-ed Cit bla-;i-(

Pier,i- +. all te +le3 i3 be3t d+-e t+eter t+ e-3ure ++d +le't+'+le t+lera-,e a-d

part repeatability( +Ce>er i. te material di3t+rt3= te met+d de3,ribed bel+C ,a- be

d+-e(

He- tere are lare -umber3 +. +le3= i- a tit pit,= tere ,+uld be di3t+rti+-3= due t+

te i am+u-t +. te-3i+- +- te upper 3ur.a,e due t+ 3tret,i- a-d ,+mpre33i+- +-

te b+tt+m 3ur.a,e( i3 ,au3e3 te material -+t t+ lay .lat( i3 ,a- be a>+ided/

le33e-ed by 3taeri- te pier,i- +. te +le3( +le3 are pu-,ed i- a 3taered

patter- te- te +ter +le3 are pu-,ed i- te alter-ate 3taered patter-(

(#*9*?

Fla-;i- i3 ,utti- up a lare 3eet +. 3t+,; i-t+ 3maller pie,e3 3uitable .+r te -et

+perati+- i- 3tampi-= 3u, a3 draCi- a-d .+rmi-( .te- ti3 i3 ,+mbi-ed Cit

pier,i-($ttp://CCC(e.u-da(,+m/pr+,e33e3/metalWpr+,e33i-/

#$


40/53

Fla-;i- ,a- be a3 3imple a3 a ,++;ie ,utter type die t+ pr+du,e pr+t+type part3= +r i

3peed die3 tat ru- at "000[ 3tr+;e3 per mi-ute= ru--i- ,+il 3t+,; Ci, a3 bee- 3lit

t+ a 3pe,i.ied Cidt(

7+r pr+du,ti+- part3= te .i-al ,+-.iurati+- +. te draC- +r .+rmed 3ape -eed3 t+ bee3tabli3ed be.+re te bla-; die ,a- be built'3i-,e te bla-; 3ie a-d te 3lit Cidt 3ie

-eed3 t+ be e3tabli3ed pre,i3ely(

4.2. F-*? O,#+*

4.2.1. (,*;*?10

Fe-di- i3 te pla3ti, de.+rmati+- +. te metal3 ab+ut a li-ear ai3 Cit little +r -+,a-e i- te 3ur.a,e area by 3tre33i- te metal ab+>e it3 yield 3tre-t but -+t larer

ta- it3 ultimate te-3ile 3tre33( He- multiple be-d3 are made 3imulta-e+u3ly Cit te

u3e +. a die= te pr+,e33 i3 3+metime3 ,alled .+rmi-( e >ari+u3 be-d ae3 ,a- be at

a-le3 t+ ea, +ter= but ea, ai3 mu3t be li-ear a-d i-depe-de-t +. te +ter3 .+r te

pr+,e33 t+ be ,la33i.ied a3 a true be-di- +perati+-( B. te ae3 +. de.+rmati+- are -+t

li-ear +r are -+t i-depe-de-t= te pr+,e33 be,+me3 +-e +. draCi- a-d/+r 3tret,i-=

-+t be-di-( ara,teri3ti, +. ti3 pr+,e33 i3 3tret,i- ?te-3ile el+-ati+-@ imp+3ed +-

te +uter 3ur.a,e a-d ,+mpre33i+- +- te i--er 3ur.a,e( Si-,e te yield 3tre-t +.

metal3 i- ,+mpre33i+- i3 3+meCat ier tate yield 3tre-t i- te-3i+-= te metal

+- te +uter 3ide yield3 .ir3t= a-d te -eutral ai3 i3 di3pla,ed .r+m te ,e-ter +. te tC+

3ur.a,e3(

+-,er-i- te i--er 3ide +. te be-d= it i3 p+33ible .+r te ,+mpre33i>e .+r,e3 t+

i-tr+du,e up3etti-= Ci, C+uld ,au3e te material t+ be,+me l+-er i- te dire,ti+-

parallel t+ te be-d ai3( i3 e..e,t ,a- be,+me Luite pr+-+u-,ed i- te be-di- +.

ti,;= -arr+C pie,e3(

Still a-+ter ,+-3eLue-,e +. te ,+-diti+- +. ,+mbi-ed te-3i+- a-d ,+mpre33i+- i3 te

te-de-,y +. te metal t+ u-be-d 3+meCat a.ter .+rmi-= a pe-+me-+- ;-+C- a3

10E( Paul DeGarm+= emple Fla,;= a-d R+-ald A( K+3er= Materials and Processes in Manufacturing&pp( %)%'%)6

%0


41/53

3pri- ba,;( + .+rm a de3ired a-le= metal3 mu3t be +>er be-t i- 3u, a Cay tat up+-

3pri- ba,;= te material a33ume3 te de3ired 3ape +. te pr+du,t(

4.2.1.1. A*?, (,*;*?

A bar .+lder ,a- be u3ed t+ ma;e a-le be-d3 up t+ ")0 deree i- 3eet metal u-der

ab+ut "()mm i- ti,;-e33( e 3eet +. metal i3 i-3erted u-der te .+ldi- lea. a-d

m+>ed t+ pr+per p+3iti+-( Rai3i- te a-dle te- a,tuate3 a ,am= ,au3i- te lea. t+

,lamp te 3eet( 7urter m+ti+- +. te a-dle te- be-d3 te metal t+ te de3ired a-le(

Far .+lder3 are ma-ually +perated a-d are u3ually le33 ta- %meter3 l+-(

Fe-d3 i- ea>ier 3eet +r m+re ,+mple be-d3 i- ti- material are e-erally made +-

pre33 bra;e3( e3e are me,a-i,ally +r ydrauli,ally dri>e- pre33e3 Cit a l+-=-arr+C bed a-d relati>ely 3l+C= 3+rt= adMu3table 3tr+;e3( e metal i3 be-t betCee-

i-ter,a-eable die3 tat are atta,ed t+ te bed a-d te ram( Di..ere-t die3 ,a- be

u3ed t+ pr+du,e ma-y type3 +. be-d3( e metal ,a- be .ed i-Card betCee- 3u,,e33i>e

3tr+;e3 t+ pr+du,e >ari+u3 repeated be-d3= 3u, a3 ,+rruati+-( Seami-= emb+33i-=

pu-,i-= a-d +ter +perati+-3 ,a- al3+ be per.+rmed by i-3erti- 3uitable die3 i-t+

pre33 bra;e3= but te3e +perati+-3 ,a- u3ually be d+-e m+re e..i,ie-tly +- +ter type3

+. eLuipme-t Ce- te >+lume i3 3u..i,ie-t t+ Mu3ti.y teir u3e(

4.3. **? P,,

4.3.1. %,;*?11

Heldi- i3 a pr+,e33 i- Ci, tC+ material3= u3ually metal3= are perma-e-tly M+i-ed

t+eter by ,+ale3,e-,e= te ,+ale3,e-,e re3ulti- .r+m a ,+mbi-ati+- +. temperature=

pre33ure= a-d metalluri,al ,+-diti+-3( e parti,ular ,+mbi-ati+- +. temperature a-d

pre33ure ,a- ra-e .r+m i temperature Cit -+ pre33ure t+ i pre33ure Cit -+

i-,rea3e i- temperature( u3= Celdi- ,a- be a,,+mpli3ed u-der a Cide >ariety +.

11E( Paul DeGarm+= emple Fla,;= a-d R+-ald A( K+3er= Materials and Processes in Manufacturing&pp( &6&= &40

%"


42/53

,+-diti+-3= a-d -umer+u3 Celdi- pr+,e33e3 a>e bee- de>el+ped a-d are u3ed

r+uti-ely i- ma-u.a,turi-(

Ne>ertele33= te a>erae per3+- a3 little ,+-,ept +. te imp+rta-,e +. Celdi-

a3 a ma-u.a,turi- pr+,e33( B. it Cere -+t .+r te u3e +. Celdi-= a lare p+rti+- +. +urmetal pr+du,t3 C+uld a>e t+ be dra3ti,ally m+di.ied= C+uld be ,+-3iderably m+re

,+3tly= +r ,+uld -+t per.+rm a3 e..i,ie-tly( B- Glerma;= 3u, Celdi- pr+,e33e3 tat are

eplai-ed bel+C are applied depe-di- +- te de3ired 3tre-t= 3ape a-d time(

4.3.1.1. O:, G# %,;*?

B- +y.uel a3 Celdi-= a,etyle-e ?22@ i3 u3ed a3 .uel( A .lame i3 dire,ted t+Card3 te

Celdi- p+i-t( e metal3 t+ be M+i-ed are melted at teir M+i-t3 duri- te pr+,e33(I3ually= material3 are ti--er ta- 2mm are Celded by ti3 pr+,e33( 5+3tly bra33= 3il>er

a-d ,+pper are Celded by ti3 met+d +Ce>er ir+- ,a- al3+ be Celded(

4.3.1.2. A %,;*?12

B- ar, Celdi-= b+t te ele,tr+de a-d te C+r;pie,e be,+me part +. a- ele,tri, ,ir,uit(

i3 ,ir,uit ,au3e3 a- ar, .l+C betCee- te ele,tr+de a-d te C+r;( i3 ar, melt3

metal3 duri- Celdi-(

4.3.1.2.1. S/,;,; M,+# A %,;*? =SMA%)13

Sielded metal ar, Celdi- i3 per.+rmed by 3tri;i- a- ar, betCee- a ,+ated'metal

ele,tr+de a-d te ba3e metal( -,e te ar, a3 bee- e3tabli3ed= te m+lte- metal .r+m

te tip +. te ele,tr+de .l+C3 t+eter Cit te m+lte- metal .r+m te ede3 +. te ba3e

metal t+ .+rma 3+u-d M+i-t( i3 pr+,e33 i3 ;-+C- a3 .u3i+-. e ,+ati- .r+m te

ele,tr+de .+rm3 a ,+>eri- +>er te Celd dep+3it= 3ieldi- it .r+m ,+-tami-ati+-tere.+re te pr+,e33 i3 ,alled S5AH( e mai- ad>a-tae3 +. 3ielded metal ar,

Celdi- are tat i'Luality Celd3 are made rapidly at a l+C ,+3t(

12E( Paul DeGarm+= emple Fla,;= a-d R+-ald A( K+3er= Materials and Processes in Manufacturing&pp( &&013ttp://CCC(tpub(,+m/,+-te-t/,+-3tru,ti+-/"%2)0/,33/"%2)0W%"(tm

%2


43/53

Bt i3 te m+3t ,+mm+- ar, Celdi- pr+,e33 u3ed i- Glerma; be,au3e +. it3 l+C ,+3t

a-d Cide >er3atility( Bt pr+>ided a pr+te,ti>e atm+3pere a-d 3tabilie3 te ar,( e3e

Cere te mai- pr+blem3 +. early e..+rt3 +. ar, Celdi-( 5+re+>er= S5AH pr+>ide3 a

pr+te,ti>e ,+ati- t+ 3l+C te ,++li- +. Celdi- a-d pre>e-t te +idati+-( At te 3ame

time S5AH pr+>ide3 >ery ++d pe-etrati+- i- Celdi- pr+,e33 a-d u3ed m+3t

,+mm+-ly i- ti,; metal plate3(

4.3.1.2.2. G# T*?+,* A %,;*? =GTA%)14

e primary di..ere-,e betCee- 3ielded metal ar, Celdi- a-d a3 tu-3te- ar,

Celdi- i3 te type +. 3ieldi- u3ed( B- a3 tu-3te- ar, Celdi-= b+t te ar, a-d te

m+lte- puddle are ,+>ered by a 3ield +. i-ert a3( e 3ield +. i-ert a3 pre>e-t3

atm+3peri, ,+-tami-ati+-= tereby pr+du,i- a better Celd( e primary a3e3 u3ed

.+r ti3 pr+,e33 are elium= ar+-= +r ,arb+- di+ide( B- 3+me i-3ta-,e3= a miture

+. te3e a3e3 i3 u3ed.

4.3.1.2.3. G# M,+# A %,;*? =GMA%)15

Ga3 metal ar, Celdi- ?G5AH@= .+rmerly ;-+C- a3 5BG Celdi- ?.+r metal i-ert'a3@=

Ca3 a l+i,al +utr+Ct +. a3 tu-3te- ar, Celdi-( e pr+,e33 i3 3imilar= but te ar,

i3 -+C mai-tai-ed betCee- te C+r;pie,e a-d a- aut+mati,ally .ed= ,+-3umable Cire

ele,tr+de(

Ar+-= elium= a-d miture3 +. te tC+ ,a- be u3ed .+r Celdi- >irtually a-y metal= tey

are u3ed primarily Cit te -+-.err+u3 metal3( B- Celdi- 3teel= 3+me 2 +r 2 i3

u3ually added t+ impr+>e te ar, 3tability a-d redu,e Celd 3patter( e ,eaper 2,a-

be u3ed al+-e i- Celdi- 3teel= pr+>ided tat a de+idii- ele,tr+de Cire i3 empl+yed(

e 3pe,i.i, 3ieldi- a3e3 ,a- a>e ,+-3iderable e..e,t +- te -ature +. metal tra-3.er

.r+m te ele,tr+de t+ te C+r; a-d al3+ a..e,t te eat tra-3.er bea>i+r= pe-etrati+-=

"%ttp://CCC(tpub(,+m/,+-te-t/,+-3tru,ti+-/"%2)0/,33/"%2)0W%"(tm15E( Paul DeGarm+= emple Fla,;= a-d R+-ald A( K+3er= Materials and Processes in Manufacturing&pp( &&6'&&4

%#


44/53

a-d te-de-,y .+r u-der,utti- ?Celd p++l ete-di- laterally be-eat te 3ur.a,e +. te

ba3e metal@( Se>eral type3 +. ele,tr+-i, ,+-tr+l3 ,a- be u3ed t+ alter te Ca>e.+rm +.

te ,urre-t( i3 ma;e3 it p+33ible t+ ,+-tr+l te me,a-i3m +. metal tra-3.er= .r+m

dr+p3= t+ 3pray= t+ 3+rt',ir,uiti- dr+p3( S+me +. te3e >ariati+-3 i-,lude pul3ed ar,

Celdi- ?G5AH'P@= 3+rt',ir,uiti- ar, Celdi- ?G5AH'S@= a-d 3pray tra-3.er Celdi-

?G5AH'S@( Furied ar, Celdi- ?G5AH'F@ i3 a-+ter >ariati+- i- Ci, ,arb+- di+ide'

ri, a3 i3 u3ed a-d te ar, i3 buried i- it3 +C- ,rater(

Ga3 metal ar, Celdi- i3 .a3t a-d e,+-+mi,al be,au3e tere i3 -+ .reLue-t ,a-i- +.

ele,tr+de3= a3 Cit 3ti,;'type ele,tr+de3( B- additi+-= tere i3 -+ 3la .+rmed +>er te

Celd= te pr+,e33 ,a- be readily aut+mated= a-d= i. d+-e ma-ually= te Celdi- ead i3

relati>ely lit a-d ,+mpa,t( A re>er3e'p+larity D ar, i3 e-erally u3ed be,au3e +. it3deep pe-etrated= 3pray tra-3.er= a-d 3m++t Celd3 Cit ++d pr+.ile( Pr+,e33 >ariable3

i-,lude type +. ,urre-t= ,urre-t ma-itude= 3ieldi- a3= type +. metal tra-3.er=

ele,tr+de diameter= ele,tr+de ,+mp+3iti+-= ele,tr+de 3ti,;+ut ?ete-3i+- bey+-d te

u-@= Celdi- 3peed= Celdi- >+ltae= a-d ar, le-t(

4.4. S#, T,#+-,*+ #*; F*/*? P,,

4.4.1. S#*; (#+*?16

Sa-d bla3ti- i3 a met+d .+r i>i- la33 3ur.a,e3 a matt .i-i3 eiter .+r de,+rati+- +r

t+ redu,e tra-3pare-,y( e met+d Ca3 i->e-ted i- "&40 by a- Ameri,a-= Fe-Mami- (ilma-= C+ i3 t+ut t+ a>e bee- i-3pired by te e..e,t +. 3a-d bei- bl+C-

aai-3t Ci-d+C3 +- te Ameri,a- prairie3( +mpre33ed air .+r,e3 te abra3i>e material

tr+u te -+le +. a 3a-dbla3ti- u- a-d +-t+ te la33 3ur.a,e( Alt+u 3a-d ,a-

be u3ed= m+re e..e,ti>e abra3i>e3 Cit le33 t+i, e..e,t3 are -+C a>ailable( Sili,+-16ttp://CCC(la33+-li-e(,+m/i-.+3er>/di,ti+-ary/#)#(tml

%%


45/53

,arbide i3 ,+mm+-ly u3ed= a3 i3 ele,tr+',+ru-dum ?alumi-um +ide@( e la33 i3

-+rmally pla,ed i-3ide a 3pe,ial ,abi-et Cit arm +le3= a >ieCi- Ci-d+C a-d du3t

etra,ti+- .a,ilitie3(

B-put3 +. te pla-t ?Pr+.ile material3= 3teel plate3= 3teel pipe3 a-d ma,i-e pr+du,ti+-=rarely ,a3ti- material3@ e-ter pre'3a-d bla3ti- ma,i-e3 Cere i- material3 e-teri-

area( ere are tree 3a-d'bla3ti- ma,i-e3 i- ere( 7a,t+ry i-put3 are 3+t'bla3ted by

3peri,al rid rai-3 bier ta- mai- 3a-d bla3ti- rai-3 Ci, are applied be.+re

pai-ti- te material3( Fut ti3 .a,t+ry i3 u3i- 3teel 3+t3 Cit 3ame 3ie a-d Luality i-

pre a-d .i-al 3a-d bla3ti-( Steel plate3 Ci, Cill are bla3ted are ,arried Cit ma-eti,

a-d Ci-,e3 t+ 3a-d bla3ti- ma,i-e area(

B- Glerma;= plate3 Ci, a>e Cidt up t+ ")00 mm a-d ti,;-e33 up t+ %0 mm are

bei- bla3ted i- +ri+-tal ma,i-e( i3 ma,i-e a3 #00 mm eit( Plate3 +ter

ta- ti3 3ie are bla3ted i- perpe-di,ular 3a-d bla3ti- ma,i-e( B. te perpe-di,ular

3a-d bla3ti- ma,i-e i3 u3ed= ydrauli, li.ti- apparatu3 are li.ti- plate3 t+

perpe-di,ular p+3iti+-( Plate3 Ci, a>e ti,;-e33 are le33 ta- "0 mm i3 be-t i-

perpe-di,ular p+3iti+-( ere.+re= te3e plate3 are bei- bla3ted al3+ +ri+-tal

p+3iti+-(

Pr+.ile3 a-d pipe3 are bei- pre'bla3ted a.ter ta- ,utti- a-d drilli- +perati+-3 i-

+ri+-tal ma,i-e3= e-erally( e3e .a,t+ry i-put3 are ,arried Cit ,eili- li.ti-

Ci-,e3 a-d ,r+33e3 t+ pre'bla3ti- area(

A>ailable ma,i-e3 ,a- -+t bla3t pr+.ile/pipe Ci, i3 bier ta- )00mm

eit/diameter a-d plate Ci, a3 Cidt i3 m+re ta- 2)00 mm( e3e material3 are

tra-3mitted t+ ma-u.a,turi- area Cit+ut a-y bla3ti- +perati+-3(

- te +ter a-d= .i-al bla3ti- +. te C+r; pie,e e-able3 te pai-ti- Cell by etti-

3ur.a,e r+u-e33 +- 3pe,i.i, >alue3( ere.+re= pai-ti- material3 Cear a-d adere t+

te 3ur.a,e +. te C+r; pie,e(

%)


46/53

4.4.2. H,#+ T,#+-,*+17

eat reatme-t i3 te ,+-tr+lled eati- a-d ,++li- +. metal3 t+ alter teir py3i,al a-d

me,a-i,al pr+pertie3 Cit+ut ,a-i- te pr+du,t 3ape( eat treatme-t i3 3+metime3

d+-e i-ad>erte-tly due t+ ma-u.a,turi- pr+,e33e3 tat eiter eat +r ,++l te metal3u, a3 Celdi- +r .+rmi-(

eat reatme-t i3 +.te- a33+,iated Cit i-,rea3i- te 3tre-t +. material= but it ,a-

al3+ be u3ed t+ alter ,ertai- ma-u.a,turability +bMe,ti>e3 3u, a3 impr+>e ma,i-i-=

impr+>e .+rmability= re3t+re du,tility a.ter a ,+ld C+r;i- +perati+-( u3= it i3 a >ery

e-abli- ma-u.a,turi- pr+,e33 tat ,a- -+t +-ly elp +ter ma-u.a,turi- pr+,e33= but

,a- al3+ impr+>e pr+du,t per.+rma-,e by i-,rea3i- 3tre-t +r +ter de3irable

,ara,teri3ti,3(

Steel3 are parti,ularly 3uitable .+r eat treatme-t= 3i-,e tey re3p+-d Cell t+ eat

treatme-t a-d te ,+mmer,ial u3e +. 3teel3 e,eed3 tat +. a-y +ter material( Steel3

are eat treated .+r +-e +. te .+ll+Ci- rea3+-3:

'S+.te-i-

'arde-i-

'5aterial m+di.i,ati+-

B- additi+- t+ ti3= I'B beam3 tat are ,+-3tru,ted i- Glerma; ,a- de ,ur>ed +r be-ded

a.ter te Celdi- be,au3e +. -+- +m+e-e+u3 eat di3tributi+-( A-d 3+me Cr+-

dime-3i+-3 appear a3 a re3ult +. te3e( 7+r ti3 rea3+-= Cit p+rtable +ye- Celdi-

ma,i-e= a--eali- a-d material m+di.i,ati+- i3 applied te3e beam3(

4.4.2.1. A**,#*? P,18

e term a--eali- re.er3 t+ a eat treatme-t i- Ci, a material i3 ep+3ed t+ a-

ele>ated temperature .+r a- ete-ded time peri+d a-d te- 3l+Cly ,++led( rdi-arily=

17ttp://CCC(e.u-da(,+m/pr+,e33e3/eatWtreat/i-tr+du,ti+-/eatWtreatme-t3(,.m18Hilliam D( alli3ter= R(= Materials Science and 'ngineering& (n )ntroduction& pp( #2$

%6


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a--eali- i3 ,arried +ut t+ ?"@ relie>e 3tre33e3 ?2@ i-,rea3e 3+.t-e33= du,tility= a-d

t+u-e33 a-d/+r ?#@ pr+du,e a 3pe,i.i, mi,r+3tru,ture(

Pr+,e33 a--eali- i3 a eat treatme-t tat i3 u3ed t+ -eate te e..e,t3 +. ,+ld C+r;=

tat i3= t+ 3+.te- a-d i-,rea3e te du,tility +. a pre>i+u3ly 3trai-'arde-ed metal(

5. COMPUTER NUMERICAL CONTROL1

Alteri- te +perati- pr+,edure3 +. early N 3y3tem3 reLuired ,a-i- te ardCare

+. te ma,i-e t++l it3el.( B- te "$403 N 3y3tem3= ,+-tr+lled by dedi,ated mi-i' +r

mi,r+,+mputer3= Cere de>el+ped t+ e-able ma,i-e t++l3 t+ be readily adapted t+

di..ere-t M+b3 by alteri- te ,+-tr+l pr+ram= +r 3+.tCare( +-3eLue-tly= N ma,i-e

t++l3 are ea3ier t+ +perate a-d m+re >er3atile ta- teir N ,+u-terpart3= a-d teir

pr+rammi- i3 3impler a-d ,a- be rapidly te3ted( N 3y3tem3 ,a- be u3ed Cit a

Cide ra-e +. ma,i-e t++l3 3u, a3 milli- ma,i-e3 a-d late3( S+me 3imulate t++l

m+>eme-t3= Cile +ter3 pr+du,e tree'dime-3i+-al >ieC3 +. ,+mp+-e-t3(

"$ttp://CCC(brita--i,a(,+m/eb/arti,le'#$"6$

%4


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B- Glerma; be-di-= pla3ma ,utti- a-d 3eari- ma,i-e3 are N ba3ed( 5a-y are

eLuipped Cit rapi, di3play3 tat pl+t te 3ape3 +. te ,+mp+-e-t3 bei- ma,i-ed(

e,-i,al draCi- C+r;3+p i>e3 te ,+de +. te C+r;pie,e Ci, i3 bei- drilled +r

,ut( B- ,+-trary t+ N ma,i-e3= 3i-,e tey a>e le33 ,+-tr+l ardCare= tey are

,eaper t+ mai-tai- a-d are e-erally m+re a,,urate(

6. OPERATION SE!UENCES OF SOME PARTS

6.1. F#?'

A plate i3 3eared i- te pr+per dime-3i+-3 Cit Pla3ma utti- 5a,i-e(

Pier,i- i3 d+-e Cit N Pu-,i- 5a,i-e(

Gri-di- i3 d+-e(

e pie,e i3 3+t bla3ted(

Bt i3 al>a-ied(

e- it i3 pai-ted(

A.ter ti3 te pie,e i3 3e-t t+ te .ur-a,e eat treated a-d dried= 3+ te +perati+- i3

,+mpleted(

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6.2. Ia-ied(

e- pai-ted(

e B'Feam i3 3e-t t+ te .ur-a,e eat treated a-d dried= 3+ te pr+du,ti+- +. ti3

pie,e i3 ,+mpleted(

6.3. %,;,; P#+-'

A plate i3 aai- ,utted i-t+ tCel>e pie,e3 Cit pr+per dime-3i+-3 Cit N

ydrauli, utti- 5a,i-e(

e3e pie,e3 are ,arried t+ Celdi- departme-t a-d Celded t+eter Cit Silded

5etal Ar, Heldi- 5a,i-e(

Sur.a,e ri-di- i3 d+-e(

e plat.+rm i3 3e-t t+ 3+t bla3ti-(

e- it i3 al>a-ied(

Pai-ted(

A.ter ti3 +perati+- it i3 3e-t t+ te .ur-a,e eat treated a-d dried= pr+du,ti+- i3

,+mpleted(

6.4.*+ P#+'

A plate i3 3eared i- pr+per dime-3i+-3 Cit Guill+ti-e utti- 5a,i-e( 7+ur drill3 are ,reated by I-i>er3al Drilli- 5a,i-e(

e C+r;pie,e i3 be-ded by $0] Cit Ab,a-t ydrauli, Pre33 5a,i-e:

Gri-di- i3 d+-e(

S+t bla3ti- i3 d+-e(

%$


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e C+r;pi,e i3 pai-ted(

e- 3e-t t+ .ur-a,e eat treated a-d dried= 3+ te +perati+- i3 ,+mpleted(

6.5. C-$*,; I


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Heit: #=)00 ;

I-it 5aterial +3t: 0(40^ / ;

5aterial +3t: #=)00U0= 40 Y 2=%)0^

I-it *ab+r +3t: ""0^ / +ur

ime ReLuired t+ Pr+du,t a- B'Feam: ) +ur3

*ab+r +3t: ""0U) Y ))0^

I-it Pai-ti- a-d S+t Fla3ti- +3t: #^ / m2

Area +. a- B'Feam: 6 m2

Pai-ti- a-d S+t Fla3ti- +3t: #U6 Y "&^

I-it 5a,i-i- +3t: ""0^ / +ur

ime ReLuired t+ 5a,i-e te H+le B'Feam: %= ) +ur3

5a,i-i- +3t: %= )U") Y 64= )^A* S 7 B'FEA5: 2=%)0[))0["&[64= ) Y #0&)= )^

7.2. F#?'

R+C 5aterial: Steel Plate

Heit: %= 0 ;I-it 5aterial +3t: 0= 40^ / ;

5aterial +3t: %U0= 40 Y 2= &^

I-it *ab+r +3t: ""0^ / +ur

ime ReLuired t+ Pr+du,t a 7la: 0= ) +ur

*ab+r +3t: ""0 U"/% Y 24= )^

I-it Pai-ti- a-d S+t Fla3ti- +3t: #^ / m2

Area +. te 7la: 0= 0% m2

Pai-ti- a-d S+t Fla3ti- +3t: #U0= 0% Y 0= "2^

I-it 5a,i-i- +3t: ")^ / +ur

ime ReLuired t+ te H+le 7la: 2) 5i-ute Y 2()/6 +ur

5a,i-i- +3t: ")U2()/6 Y 6= 2)^

A* S 7 E 7*AG: 2= &[24= )[0= "2[6= 2)Y#6= 64^

)"


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8. CONCLUSION

e 3ummer pra,ti,e pr+ram a3 a bi imp+rta-,e .+r me,a-i,al e-i-eeri- tird

year 3tude-t3( A ma-u.a,turi- ,+mpa-y Ca3 e-tirely +b3er>ed duri- ti3 3ummer

pra,ti,e a-d +. 3+me te+reti,al a-d pra,ti,al ;-+Clede ab+ut e-i-eeri- draCi-

a-d pr+du,ti+- te,-iLue3 .r+m te ,+ur3e3 5E ""#= 5E ""%= 5E 200 a-d 5E 202

Ci, are i>e- i- te .ir3t a-d 3e,+-d year3 Ca3 impr+>ed Cit pra,ti,al appli,ati+-3(

)2


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Al3+= a- eperie-,e i3 ai-ed i- te real C+r;i- li.e( Stude-t3 be,+me m+re .amiliar

Cit C+r;i- ,+-diti+-3 +. a ,+mpa-y(

*+t3 +. be-e.i,ial ;-+Clede i3 lear-ed by te 3tude-t3( 7ir3tly= 3tude-t3 met Cit a l+t +.

-eC 3y3tem3( H+r;i- pri-,iple3= pr+du,ti+- pr+,edure3 a-d imp+rta-,e +. te3e 3tep3are lear-ed( e 3y3tem3 +. 3+me u-iLue a-d m+der- pr+du,ti+- te,-iLue3 3u, a3

N +perati+-3 Cere ,are.ully eami-ed( e pr+du,ti+- 3tep3 +. 3pe,ial part3 Cere

eami-ed a-d te 3+rte3t a-d te m+3t e,+-+mi,al Cay are lear-ed( e e-eral

l+,ati+- +. ea, pr+du,ti+- u-it a-d te e..i,ie-,y +. pr+,e33e3 eami-ed( e mai-

di..ere-,e3 betCee- te m+der- a-d traditi+-al ma-u.a,turi- te,-iLue3 are

pra,ti,ed( e3e -eC 3y3tem3 pr+>ide 3tude-t3 a re3ear,i- a-d impr+>i- >ieC(

e imp+rta-,e +. e-i-eeri- detail3 Ca3 lear-ed( e imp+rta-,e +. te,-i,al

draCi-3 a-d rapi,al repre3e-tati+- Cere u-der3t++d( 5+re+>er= duri- ti3 3ummer

pra,ti,e pr+ram 3tude-t3 impr+>ed teir 5S ..i,e a-d Aut+'AD ;-+Clede(

B- ,+-,lu3i+-= Glerma; i3 a e-erally 3uitable ,+mpa-y .+r 5E #00 3ummer pra,ti,e(

E-i-eer3 a3 u3ually ++d C+r;i- ,+-diti+-3 Cile C+r;er3 a>e -+t tat mu,(

Fe3ide3= 3a.ety i3 3+metime3 -ele,ted by te C+r;er3( Ce- te 3ummer pra,ti,e= .+ur

C+r;er3 a,,ide-t appe-ed( 7+r better e..i,ie-,y= Glerma; 3+uld i>e m+re atte-ti+-

t+ 3y3temati, C+r;i- a-d pla--i-( Al3+= tere 3+uld be m+re ,+-tr+lli- 3y3tem3 tat

are >ery imp+rta-t .+r de,rea3i- +perati+- time +. pr+du,t3(

Middle East Technical University[1][1].Son3

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