DESCRIPTION OF THE COMPANY

The name of the company

TEMSAN Turkish Electromechanics Industry (Circuit brakers&disconnectors Factory)

The location of the company

Badat Caddesi, Ostim yolu 06370 Macunky, Ankara

Phone: 0312 397 55 75 (8 Lines) Web: www.temsan.gov.tr E-mail: idemirhan@temsan.com.tr

Plant Area
Total closed area: 98.349 m2 Total area: 25.889 m2

Organization structure of the company

+ Organization structure of the company is given in Appendix A

Number and duties of engineers employed

16 engineers are employed in company: + 8 Mechanical Engineers + 4 Electronic Engineers + 3 Electric Engineers + 1 Industrial Engineer

Duties of Department of Manufacturing Engineering

Determination of the location in the factory where operations will take place Designation of the cutting tools Design of the necessary fixing tools and supports Measuring and checking process times Investigation of the production capacities of the machines Deciding on how products will be produced according to the technical drawing Preparing follow-up and operation files which show the production steps of a work piece

Duties of the Department of Assembly Engineering

To follow new technologies Making arrangements for the equipment supplement Organize the mechanical production and be responsible from the assembly lines To control production and manufacturing and solving the problems during the assembly

Duties of the Department of the Re & De Engineering

Design and development of new products Redesign and development of new products when error occur after sale Computer aided design (2D and 3D) Transmission testing Engine testing

Duties of the Engineers at Assistance Service Area

Education of the operators in order to increase the quality and productivity Planning of the heat treatment, dyeing, covering machines and operators in order to increase productivity

Duties of Engineers at Quality Assurance Department

Preparing the list of the cost of the materials Testing the machines whether they are made properly or not Determining the policy and aims of the company and find out the standards to be followed Providing continuity of the production quality

Main area of the company

The company is aimed at installing, operating, rehabilitating hydro electric power plant by realizing investment, production and erection works related with the switch equipment, power transformers turbo and hydro generators, hydro turbines used for the electrical energy generation and distribution The mission of the TEMSAN is to increase the electrical energy generation which is the indication of the civilization and comfort, to get additional value by this generation and to increase the electrical equipment production; indicating knowledge, skill and technological power. TEMSAN, Turkish Electromechanics Industry studies on two different areas generally. In Diyarbakir (Hydraulic Turbine and Generator Factory) and in Ankara (High Voltage and Medium Voltage Circuit Breakers and Disconnections Factory OYKAF-), the company is making production. In the part of the company which is situated in Ankara, some sort of circuit breakers and disconnectors are produced. These products are: Medium and High voltages, vacuum packed and SF6 gas filled breakers Command and relay panels Metal clad cubicles for the hydro electric power plants Step down transformer substations

Control command, measuring and protection systems for the hydro electric power plants

The products leave the factory after production processes. Some parts of these products are sold to some sort of factories or service areas, and other parts are purchased by some electrical companies and used all over the Turkey. There are approximately 2000-3000 components in the structure of the circuit breakers and disconnectors. Most of these components are produced in Ankara factory, but the components which are found as standard are purchased from the industry. In Diyarbakir Factories: Hydro electric turbine Butterfly vane Draft tube (cone and connection element) Turbine head covers and rings Speed governors and tanks Turbine pit liners are produced.

A brief history of the company

TEMSAN is the first and unique Turkish Company with a successful past of 32 years in the sector of production, establishment, operation and maintenance service of energy installations with the two factories in Ankara and Diyarbakir. TEMSAN started its production at 09.02.1977 in Diyarbakir. The constitutive-associations of the company are: TEA Turkiye Elektrik retim letiim A.. Trkiye Kalknma Bankas A.. Makina ve Kimya Endstri Kurumu 4

Turkiye Seker Fabrikalar A.. Turkiye Vakflar Bankasi A.O.

In 1984, Ankara Factory of TEMSAN has been established by German Siemens Company, and then in 1987 factories has started to continue production as a foundation of ller Bank. As a result, in 1994 these factories have been purchased by TEMSAN. The company has been established as a joint-stock company and listed in the Ankara Trade Association with the 34690 register number. The production capacity of the Ankara M.V and H.V circuit breakers and disconnectors factory is 4200 M.V circuit breakers a year or equivalence product to this quantity. In TEMSAN A.. M.V and H.V circuit breakers and disconnectors Factory; planning, projecting, researching, developing, purchasing, and service labor are performed and these are suitable for TS-ISO 900 standards.

INTRODUCTION

Subject
The subject is to examine the production and production techniques.

Aim
The aim of the ME 300 summer program for the junior year students of Mechanical Engineering Department is to improve the theoretical and practical knowledge on production techniques and engineering drawing acquired in the previously completed course work (ME 113, ME114, and ME 202) Theoretical knowledge is very important at the engineering part of a product. The engineer must know the criteria for the proper design of the product. However, theoretical knowledge

alone is not sufficient to manufacture a product. Some perfect designs might be developed with only theoretical knowledge, but such designs might not be manufactured because of some impossibities. Therefore, practical knowledge has a great importance in the education of an engineer. In the Mechanical Engineering Department opportunities to give students some practical knowledge is limited. It is difficult to understand the production techniques learned in me 202. Thus, the summer practice is a great chance for students to observe various production techniques employed in companies. Also, an engineer have to learn how to make technical drawings, how to arrange these drawing and how to read others technical drawings. Theoretical knowledge gained in ME 113 and ME 114 should be practiced in real life and summer practice is an opportunity for this aim. In the following summer practice report, production techniques employed in TEMSAN, machines and their uses in the organization, technical drawings are examined and production and cost analysis of sample pieces observed are cited and explained in detail.

REPORT
The following various types of production techniques are being used in TEMSAN in order to achieve the highest quality of products.

CHIP REMOVAL PROCESSES

Metal cutting, commonly called machining, is the removal of unwanted portions from a block of material in the form of chips so as to obtain a finished product of desired shape, size and finish. Vast majority of manufactured product require machining at some stage in their production, ranging from relatively rough work to high precision work. Thus, metal cutting is the most important of the basic manufacturing processes. In all metal cutting operations an edged tool is driven through material to remove chips from the parent body and leave geometrically true surfaces. The kind of surface produced by the operation depends on the shape of the tool and the path it traverses through the material. The properties of the work material are important in chip formation. High strength materials require larger forces than do materials of lower strength, causing greater tool and work deflection, increased friction and heat generation and operating temperatures, and s requiring greater work input. The structure and composition also influence metal cutting. Hard or abrasive constituent, such as carbide in steel, accelerate tool wear. Work material ductility is an important factor. Highly ductile materials not only permit extensive plastic deformation of the chip during cutting, which increases work, heat generation, and temperature, but it also results in larger continuous chips that remain in contact longer with the tool face, thus causing such as gray cast iron, lack the ductility necessary for appreciable plastic chip formation. Consequently, the compressed material ahead of the tool fails in brittle manner along the shear zone, producing small fragments. Such chips are termed continuous or segmented. 7

Metal cutting covers the major parts of the production made in the mechanical production of TEMSAN. The types of metal cutting processes used are as follows: Turning Drilling Milling Broaching Grinding Lapping Honing Sawing CNC Machining

Turning
Turning widely used for machining external cylindrical and conical surfaces. The work piece rotates and longitudinally fed single point cutter does the cutting. External cylindrical, conical and irregular surfaces of limited length can also be turned by using a tool having a specific shape and feeding it inward against the work. The shape of the resulting surface is determined by the shape and size of the cutting tool. Machine tools used for this process are called lathes. Besides turning, lathes are capable of performing a variety of processes as given below. a) Facing: Cutting tool must be fed towards only surface of the work piece in order to set clean and flat surfaces. Thus, the rough surface is removed. b) Cutting: If the tool is fed only towards the work piece, that section of work piece is cut along the position of tool. c) Drilling: Drilling on lathes is done with the drill that is in the tailstock. Tailstock fed by hand against work piece. Only work piece rotates and drill does not. d) Boring: Lathes is used for enlarging a hole that is previously drilled. This process is called boring. 8

In TEMSAN A.. chip removal processes are the most used processes. Parts with axial symmetric profiles and most of the circuit breakers and disconnectors are produced by turning operations.

Drilling
Drilling is used for making holes or enlarging holes. The important steps of the drilling processes are; firstly the upper point of the drill forms very small hall. As the drill goes through against the material, chips start to form. Then chips are removed from the hole by means of special shapes of drills. Because of friction between material and drill, temperature may get undesired values. Lubrication fluid can be used in order to decrease the temperature. Drills are of six types. The most common types of drills are twist drills. These have three basic parts; the body, the point and the shank. The body contains two ore more spiral grooves called flutes in the form of a helix. The flutes serve as channels through which the chips come out of the hole and permit coolant to get to the cutting edges. Other types of drills are deep hole drills, trepanning cutters, center drills, countersinks, spade drills and special combinations drills. Basic components of drilling machines are; base, column, power head, spindle and worktable. Work can be held in a jig or fixture that is placed on the table. For too big work pieces, it can be clamped directly the worktable. Drilling is used widely in TEMSAN, but there are much less drilling machines compared parts need to be drilled, because of the drilling capacity of lathes and milling machines.

MILLING
In this process, multiple-tooth cutter is used so that cheap removal rate is very high. Its job is mainly same with shaping but milling process is faster. Mostly the cutter rotates and work piece is fed to a cutter. At some milling machines, work pieces remain stationary and cutter is fed to the work piece. Milling processes can be generated by two different methods.

Up milling is the traditional method and it called conventional milling. The cutter rotates against the direction of the work pieces. In climb or down milling, the rotation is the same direction as the feed. The method of chip formation is completely different in two cases. In up milling, the chip is very thin at the beginning, and increases in thickness become maximum where the tooth leaves the work. In down milling, maximum chip thickness occurs close to the point at which the tooth contacts the work. The surface quality of the work piece is better than up milling because cutting process is smoother. There are generally two types of milling operations: Peripheral milling Face milling

In peripheral milling the surface is generated by teeth located on the periphery of the cutter body. The surface is parallel with the axis of rotation of the cutter. In the face milling, the generated surface is at right angles to the cutter axis. Most of the cutting is done by the peripheral portions of the cutter teeth. Milling is one of the most used production techniques in TEMSAN. Especially down milling is preferred with respect to up milling because of the higher surface quality. Horizontal or vertical milling is selected depending on the parts of circuit breakers or disconnectors.

Broaching
Broaching is a unique machining process in which chips are removed by a number of successive teeth increasing in size, built on a long tool named broach. Roughing, semi finishing, and finishing teeth, consequently the related processes are combined in a single tool. The profile of the machined surface is the inverse of the profile of the broach. The cutting action is performed in a fixed path, and with one stroke of the broach, the process is completed. Broaching is suitable for mass production where the high production rate justifies the cost of the expensive tool.

10

A broach is composed of a series of teeth, each standing slightly higher than the last. This rise per tooth, also known as step, determines the depth of cut by each tooth. The frontal contour of the teeth determines the shape of the resulting surface. As the result of these conditions built into the tool, no complex motion of the tool relative to the work piece is required and the need for the highly skilled operators is minimized.

Grinding
Grinding is a process which moves relative a surface in a plane while a grinding wheel contacts the surface and removes material, such that a flat surface is created. Produce a very flat surface, very accurate thickness tolerance and cutting tool sharpening are some of the reasons of grinding.

Honing
Honing uses fine abrasives stones to remove very small amount of metal. It used to size and finished bored holes; removing common errors left by boring, or remove the tool marks left by grinding. In honing internal cylinders a small rotation is combined with an oscillatory axial motion. Also, super finishing is a variation of honing which results in surfaces of very uniform, repeatable smoothness. It is not a process of changing dimensions, but only improves surface finish.

Lapping
Lapping is an abrasive surface finishing process where in fine abrasives particles are charge into a soft material called a lap. It is a slow metal removing processes, and is used only to remove scratch marks left by grinding or honing or to obtain very flat and smooth surfaces.

11

Abrasive machining (grinding, honing, and lapping) is used in production of most parts where surface quality is important in TEMSAN. Usually surface quality achieved by grinding is enough but in rotating and moving parts more quality is needed; so super finishing or lapping are applied to those parts.

Sawing
Sawing is a basic machining process in which chips are produced by a succession of small cutting edges or teeth, arranged in a narrow line on a saw blade. Each tooth forms a chip progressively as it passes through the work piece and the chip is contained within the space between two successive teeth pass from the work. Sections of considerable size can be severed from the work piece with the removal of only a small amount of the material in the form of chips. Sawing is the most probably the most economical of the basic machining processes with respect to the vast of material and power consumption, and in many cases with respect tot the labor.

CNC Machining
Numerical control is a method of controlling the motion of machine components by means of numbers or coded instructions. When the data handling, control sequences and response to input is determined by the microprocessors it is called CNC. This system includes preconception, planning and coding of all necessary machine motions and functions by a programmer followed by a transmission of these instructions to the machine control, which activates machine functions.

12

JOINING PROCESSES WELDING

In TEMSAN the applied methods of welding are as follows:

Arc Metal Welding

The arc is struck with no additional shield gas supply, between the consumable electrode fed from the coil and the work. The electrode also acts as a filter. The metals are being joined are melted at the points where welding occurs. Head is obtained by an arc between the work and the electrode. Composition of the consumed materials and weld quality depends on the skill of the operator.

Gas Metal Arc Welding (GMAW)

The process is similar but the arc is now maintained between the work piece and the wire electrode. The consumable wire electrode provides the filter metal. An inert gas is supplied with sufficient flow to form an invert shield around the arc and the molten pool of metal, therefore shielding them from the atmosphere.

Oxy-fuel Gas Cutting

All thermal cutting is done by oxy-fuel cutting. The metal is melted by means of the flame of the oxy-fuel gas torch and then liquid metal is expelled from the joint by the gas stream.

Resistance Spot Welding (RSW)

Resistance spot welding is the simplest process of the resistance welding processes. By this process, all of the commercial metals can be spot welded to each other.

13

If proper current and timing, electrode shape, electrode pressure and surface conditions are maintained, spot welds can be obtained with excellent quality. There are several types of spot welding machines. For light production work the simple rocker-arm machine is used. At this machine the upper electrode is moved by means of a food pedal. On larger machines or machines for larger amounts of work , the electrode movement can be obtained by an electric motor or an air cylinder. In TEMSAN, welding is used for joining the components of circuit breakers and disconnectors or for repairing any kind of broken material and device.

HEAT TREATMENT PROCESSES

Heat treatment is the controlled cooling and heating of metals to alter their physical and mechanical properties without changing the product shape. Heat treatment is sometimes done inadvertently due to manufacturing processes that either heat or cool the metal such as welding or forming. It is often associated with increasing the strength of material, but it can also be used to alter certain manufacturability objectives such as improve machining, improve formability, and restore ductility after a cold working operation. Thus, that is very enabling manufacturing process that can not only help other manufacturing processes but also improve product performance by increasing strength or other desirable characteristics. Steels are particularly suitable for heat treatment, since they respond well to heat treatment and the commercial use of steels exceeds of any other material. In TEMSAN, nowadays, the heat treatment department is not very active, but some row materials comes as cast, so some of the heat treatment processes such as tempering and normalizing are applied before further processing.

14

Tempering
Steel, which has been quenched directly into the martensitic region, is too brittle for most purpose and must be softened. Moreover, transformation of austenite to martensite outcome high stresses. Therefore, tempering which solves the brittleness problem and gives the material a full structure is applied. Martensite is strong and hard but relatively brittle. When material is tempered, strength and hardness decreases, but the ductility and toughness increases.

Normalizing
Normalizing is the process of raising the temperature to over into the austenite range. It is held at this temperature to fully convert the structure into austenite, and then removed from the furnace and cooled at room temperature under natural convection. This results in a given structure of fine pearlite with access of ferrite or cementide. The resulting material is soft; the degree of softness depends on the actual ambient conditions of cooling. This process is considerably cheaper than full annealing, since there is not the added cost of controlled furnace cooling.

METAL FORMING PROCESSES

BENDING
Bending is the plastic deformation of the metals about a linear axis with little or no change in the surface area by stressing the metal above its yield strength but not larger than its ultimate tensile strength. When multiple bends are made simultaneously with the use of a die, the process is sometimes called forming. Plastic bending differs form 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. The various bend axes can be at angles to each other, but each axis must be linear and independent of the others for the process to be classified as a true bending operation and be treatable by simple bending theory. If the axes of deformation are not linear or not independent, the process becomes one of drawing or stretching not bending.

15

Characteristic of this process is stretching imposed at the outer surface and compression on the inner surface. Since the yield strength of metals in compression is somewhat higher than the yield strength in tension, the metal on the outer side yields first, and the neutral axis is displaced from the center of the two surfaces. Because of the preferred tensile deformation, the metal is thinned somewhat at the bend, thinning being pronounced in the center of the sheet where the material can not freely pull in along the axis of the bend. a) Angle Bending: A bar folder can be used to make angles bends up to 1500 in the sheet metal fewer than 1.5 millimeters thick. The sheet of metal is inserted under the folding leaf and moved the proper position. Raising the handle actuates a cam causing the leaf to clamp the sheet. Further motion of the handle, bends the metal to the desired angle. Bar folders are manually operated and are usually less than 4 meters long. Bends in heavier sheet or more complex bends in thin material are generally made on press breakers. These are mechanical or hydraulic presses.

b) Roll Bending: Plates, sheets and rolled shapes can be bended to a desired curvature on forming rolls. These machines usually have three rolls in the form of a pyramid, with the lower rolls being driven and the position of the upper roll being adjustable to control the degree of curvature. When the rolls are supported by a frame on each end, one of the supports can often be swung clear to permit the removal of closed shapes from the rolls. Roll bending machines are available in a wide range of sizes, some being capable of bending plate up to 150 mm thick.

SHEARING
Shearing is mechanical cutting of materials without the formation of the chips or the use of burning or melting. When the two cutting blades are straight, the process is called shearing. When the blade geometry is curved, as in the edges of punches and dies, the process has special names, such as blanking, piercing, notching, shaving and trimming.

16

In the simple type of shearing processes, as the punches descend against the work piece, the metal is first deformed plastically into the die. Because the clearance between the two tools is only 5% to 10% of the thickness of the metal being cut, the deformation is highly localized. The punch penetrates into metal, the material flows into the die and the opposite surface bulges slightly. When the penetrations reaches about 15% to 60% of the thickness of the metal, the amount depending on the material ductility and strength, the applied strength exceeds the shear stress and the metals suddenly shears or ruptures through the reminder of its thickness. The two stages of shearing processes; deformation and fracture can often be seen on the edges of sheared parts. If the punch and die have proper clearance are maintained in good conditions, shared edges may be produced that are sufficiently smooth to use without further finishing. The quality of the shear 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 alignment and the movement of the piece through the die is restrained with an opposing plunger or rubber die cushion applying pressure from below the work piece. These measures cause the shearing to take place uniformly around the edge rather than randomly at the weakest points.

FORGING
Forging is the process in which metal, cold or heated, is shaped into component geometry through the use of multiple blows with a drop hammer or through the application of pressure with a hydraulic press. For most forging processes, a set of dies are required. Due to grain orientation, forgings are a desirable choice when high strength and excellent fatigue life is required for the component. Many materials can be forged including aluminum and steel.

17

INFORMATION ABOUT MACHINES USED

Engine Lathes
These are heavy duty machine tools which have power drive for all tool movements except on the compound rest. They have chip pans and a built in coolant circulating system. Engine lathes are used for rough operations, usually in first steps of projects. There are 5 universal lathes. TEZSAN Universal Lathes Number of machines: 5 Model: SN 50 Total Length: 3575mm Weight: 1815kg Total Width: 2000mm Total Height: 1150mm The Voltage of electric motor: 380V Motor Power: 5.5/7.5 kW/HP Max Diameter of work piece: 500mm Turning Length: 2000mm Coolant Volume: 45L Electric Pump Power: 0.15 kW Diameter of Chuck Hole: 65mm

Semi-Automatics Lathes
There are 14 of these lathes in manufacturing shop of the factory to manufacture circuit breakers and disconnectors parts.

MONFORTS Semi-Automatics Lathes Number of machines: 5 18

Model: FAR 1042 Power: 11 kW Turning diameter: 340 mm Normal turning length: 150mm Max stroke cross slides: 115 mm

INDEX Semi-Automatics Lathes Number of machines: 9 Model: ER 42 Max diameter admitted: 220 mm Max diameter treating: M30 Max broaching depth: 110 mm Max turning angle: +15, -30

Milling Machines
Milling machines has an important role in the production stage of all parts in TEMSAN. Very accurate operations are needed because parts machined are critical components of circuit breakers and disconnectors. Horizontal Milling Machines These machines have a horizontal hollow spindle in the column to drive cutters. There are 3 horizontal milling machines in the machine shop of the factory.

FRITS WERNER Horizontal Milling Machines Number of machines: 3 Model: HF 3 Power: 11 kW, 15 HP Min-Max RPM: 35.5 1800 X Y- Z axis format: 1200- 310- 400 mm Max mandrel diameters: 27 mm

19

Mandrel Conicity: DIN 2080

Universal Milling Machines Universal milling machines are like horizontal milling machines except that the table can be swiveled in a horizontal plane. There are 5 universal milling machines in the factory to manufacture circuit breakers and disconnectors parts.

DECKEL Universal Milling Machines Number of machines: 5 Model: FP 346 Power: 4 kW / 5.4 HP X- Y- Z axis format: 800- 300- 400 mm Y- Z auxiliary axis format: 100-100 mm Min- Max press diameter: 0.5- 25 mm Mandrel Conicity: ISO 40 Table working surface: 1000x440 mm Min- Max RPM: 25- 2500

Vertical Milling Machines In vertical milling machines the controls are similar to those of universal models. The vertical milling machines are particularly useful in tool and die work, where elevations, depressions, slots etc. are called on the work piece. There are two vertical milling machines in the machine shop of the factory.

HECKERT Vertical Milling Machines Number of machines: 2 20

Power: 11kw / 15 HP X- Y- Z axis format: 1120- 360- 400 mm Z axis auxiliary axis format: 110 mm Min Max RPM: 28- 800 Table working surface: 1600x400 mm

CNC Machining
There is one CNC horizontal machine in machine shop of the factory for mass production of the circuit breakers and disconnectors parts. FINN Power CNC Horizontal Machine Number of machines: 1 Model: X5 Power: 18.5 kW Face milling: 275 RPM End milling: 180 RPM Drilling: 660 RPM Tapping: 61 RPM Table working size: 600x600 mm Axis Stroke: X- 1250 mm, Y- 1000 mm

Drilling Machines
Some drilling machines are used for basic hole making operations in various types of parts in TEMSAN. Drilling holes, increasing holes, and countersink operations are some of machining operations that are made in these drills.

Radial Drills

21

Radial drills are convenient for heavy work pieces that can not be moved around easily or, are too large for other kinds of drill presses. The drill spindle is fed up and down by hand or power.

ALLZMETALL Radial Drills Number of machines: 9 Power: 2.4 kW / 3.2 HP Min- Max RPM: 56- 1250 Max drill diameter: 50 mm Table working surface: 560x470 mm Head turning angle: 360

SOLID Drilling Machines Number of machines: 5 Model: B 35 VS Power: 2.9 / 3.9 HP Min- Max RPM: 70- 1200 Max Drilling diameter: 60 mm Table working surface: 2100x400 mm

SOLID Drilling Machines Number of machines: 4 Model: R 16 S Power: 0.74 / 1HP Min- Max RPM: 250- 4000 Max drilling diameter: 70 mm Table working surface: 1400x400 mm

SOLID Drilling Machine 22

Number of machines: 8 Model: R 16 Power: 0.74 kW / 1HP Min- Max RPM: 200- 2800 Max drilling diameter: 70 mm Table working surface: 2100x400 mm

Presses
Eccentric and hydraulic presses are used for mainly in mechanical workshop of TEMSAN. Presses with 80 tons capacity and hydraulic presses with 40 tons capacity can be used for cold shaping processes.

DARLEY ARKANT Hydraulic Presses Number of machines: 3 Max pressing force: 40 tons Max length: 3100 mm Max descent speed: 100 mm/min Max ascent speed: 150 mm/min Stroke: 100 mm/min Power: 5.5 kW

DARLEY ARKANT Eccentric Presses Number of machines: 3 Max pressing force: 80 tons Stroke: 150 mm/min Power: 5.5 kW

Welding

23

MIG / MAG Welders are used to permanently assembly the components of circuit breakers together.

MESSER GREISHEM Gas Welding Machines Number of machines: 7 Welding Voltage: 10- 24 V Output current: 20 / 300 A

MESSER GREISHEM CNC Oxy Cutting Machine Number of machines: 1 Max cutting dimensions: 3000x3100 mm Min- Max cutting thickness: 3- 200 mm Max cutting speed: 1000mm/min Cutting point: 4

Other Machines in Machine Shop

TACHELLA Universal Grinding Machines Number of machines: 2 Motor Power: 2.5 kW Max grinding diameter: 250 mm Working surface: 900x205 mm Min- Max RPM: 2200- 3200 Table turning angle: 360

STEINEL Riveting Machine

24

Number of machines: 1 Max riveting diameter: 9 mm Max pressure: 260 KP Max stroke: 55mm/min Min Max motor RPM: 1400- 2800 Power: 2.2 kW

Guillotine Cutter Cutting capacity: 14x1500mm 16x800 mm

SOLO Temper Furnace Number of machines: 1 Connection Voltage: 3x 380 V Max heating: 1050 C

25

PRODUCTION ANALYSIS OF SAMPLE WORK PIECES

Wicket Gate (Regulating Panel)
Material: GX4CrNi 13-4- Q1 Material Number: 1.4317 Drawing Number: D.22332.30.034 Operations Applied Cast material comes to the machine shop. The material is controlled. Rough turning operations are applied at TEZSAN SN 50 lathes. Ultrasonic controls are applied. At this step, if a problem occurs in the casting part of material (holes, crack), production is stopped and problem is solved by using stainless electrodes at casting part If there is no problem, manufacturing process continue with turning operations.

The work piece is fixed to the chuck of TEZSAN SN 50 lathes again. M20 X 42 hole is drilled Using a mandrel, 100f7 x 140 and 110d9 x 240 holes are drilled and tapped. 120f7 x 100 and 190 x 10 holes are drilled.

Work piece is reversed and fixed to the chuck again. 90f7 x 125 and 140 x 10 holes are drilled and tapped.

At FRITZ WERNER Horizontal milling machine, milling operations for the casting part (wicket) is applied. (Wicket cutting). Wicket part is rubbed. The work piece is washed and cleaned all chips and dried with air.

26

Wicket gates are used for regulating water amount which is used for hydro electric power plants. With the help of wicket gates, small or large amount of electric power is produced which depends on public requirements.

Key Part of Connector

Material: S235J263 Drawing Number: D.42673.036 Operations Applied The material is controlled. Steel work piece is cut roughly with MEISSER GREISSEM CNC oxy cutting machine. In milling and drilling department of machine shop, cleaning step is done. Using an apparatus, the work piece is fixed at the HECKERT Vertical milling machine. 14 x 4 holes are drilled. 7 x 3 holes with 5 mm deep are drilled. 60 degree incline is given two of outer surface. The height of work piece is reduced from 40 mm to 34 mm. The work piece is reversed. 41 mm width and 5 mm deep chamfer operation is done. 275 mm work piece width is provided.

At SOLID Radial drill, M16 x 4 gear operations are applied. The work piece is washed and cleaned from all chips and dried with air.

This key part is used for the connection part of stators at Alpaslan Hydro Electric Power Plant in Turkey.

27

Laminated Rim
Material: 42 CrMo 4 Drawing Number: D.42596.599.031 Operations Applied Material comes to the machine shop with large dimensions. Material is controlled To achieve desirable dimensions, sawing operations are applied. At TEZSAN SN 50 Universal lathe, turning operations are applied: 40 mm outer diameter is reduced to 38 mm. Work piece is reversed in order to reduce outer diameter of other part to 38 mm (because of the long length of work piece) M36 x 2 gear operations are applied to the two end of work piece.

Work piece is washed and cleaned from all chips and dried with air. As a covering operation, material is covered with galvanize.

In order to prevent vibration of the work piece, resulted from long height, special mandrels used on lathes. In order to prevent thermal disadvantages, lubricating oil is used during the turning operations.

Laminated rim is used for the connection of the stators at the side points at Alpaslan Hydro Electric Power Plant in Turkey.

28

29

30