Contents

Description of Company....2
Introduction ..8
Report..9
o Production Techniques
Chip removal processes........9

Turning.10
Drilling..10
Milling...11
Broaching....12
Sawing.13
Hobbing...13

Abrasive Machining processes...14

Welding....15
Tempering ..16
o Production Analysis of Sample Workpieces
Part 117
Part 218
Part 318
Part 419
Part 521
Part 622
o Information About Machines Used..24

Conclusion......32
Appendix .....33

Description of Company
Company name: Trk Traktr ve Ziraat Makinalar A..
Company location: Gvercin Yolu 111/112
Tel:
(0 312) 211 01 90
Fax:
(0 312) 211 03 73
(0 312) 211 00 31
Web:
http://www.turktraktor.com.tr
E-mail: turktraktor@turktraktor.com.tr
Atatrk Orman iftlii
Gazi / Ankara
History of Trk Traktr
The project, which started at Atatrk Forest Farm in 1945 to
manufacture aircraft engine, had been finalized within 3 years, and the
factory was officially inaugurated on 30th October, 1948. The factory,
which had to be closed down due to insufficient orders, was transferred to
Makina ve Kimya Endstrisi Kurumu (MKEK a state enterprise dealing
with machinery and chemical products) in 1952. In 1954 a new company
called Minneapolis Moline Trk Traktr ve Ziraat Makineleri A. had
been established with head office in Ankara, and the factory began its
operations after an operation agreement had been signed with
Minneapolis Moline Co. of the U.S. and personnel had been recruited.
Establishment of the company was approved by a Cabinet decision,
which was then published in the official gazette dated 29th July, 1954. It
started to function in Atatrk Orman iftlii in an area of 280 000 m 2.
Until 1963 different types of Minneapolis tractor models were produced
and the transfer of production technology was provided. At 1963
Minneapolis Moline decided to change its production strategy and
decided to end the production of low powered tractors so the agreement
with Trk Traktr ended. Thereupon Trk Traktr had a license
agreement with FIAT Trattori and continued its tractor production. In
1963, after the license agreement with Fiat, a commercial agreement was
made with Egemak, Fiats representative in Turkey. In 1968 the name of
2

the factory was changed to Trk Traktr ve Ziraat Makineleri A...

When the company was established, its capital was 20,000,000TL which
is more than 50 million YTL today.

Trk Traktr is the first manufacturing company of Turkish

automotive industry. The partnership company of Ko Holding and CNH,
Trk Traktrs % 25 shares is offered to public, at June 2004. The
companys capital is shared by Ko Holding with 37.5% and CNH with
37.5%.

Annual production capacity is 35,000 tractors. It is the leader of the

domestic market with a market share of 60%. Trk Traktr having started
the manufacture of newly designed TD and JX series tractors in 2002 in a
power range of 50 - 95 HP which are combining the features of utilization
comfort and low-emission, environment friendly engine, Trk Traktr is
now exporting its products to more than 50 countries including USA. The
company having approximately 1014 employees including 67 engineers
derive its strength from the experienced employees and 250 suppliers
spread all over the country. Since its establishment, being conscious about
its social responsibilities, Trk Traktr has continuously supported the
countrys economy and sustainable development.
Computers are widely used in Trk Traktr Plant. MRP/ERP
(Manufacturing Resource Planning / Engineering Resource Planning)
package was received from the Oracle firm and the implementation work
started. Turkish Tractor was to use, on the one hand, high technology in
the manufacturing of very important tractor components and, on the other
hand, advanced systems in the control and planning of manufacturing.
The control of manufacturing, started 35 years ago with a wall board and
cartotex which was the application of a simple GANT chart, was to be
brought to the level of contemporary automotive producers.

Detailed Organization Chart is in Appendix.

You can see computers at every point of the plant. Masters of the
workers records the data to computers. The codes of the worker, machine
and work are recorded. In Turk Tractor every computer has at least
Windows 98 operating system. Besides to this Microsoft office programs
are widely used.
There are special areas that computers are widely used. Construction
department is one of these special departments. There are 5 Silicon
Graphics (SGI) workstations in this department. The software on these
computers is
IDEAS-2D
AUTO-CAD RELEASE 14
AUTO-CAD REALASE 2000
AUTO-CAD programs are especially used on Layout drawings
Research & Development is another special department. At this
department, there are 6 SGI workstations and 14 PCs. Software used in
this dept are:
Pro/ Engineer Advanced Design Pack and different modules of this
program
IDEAS 2D Master Series V5
ANSYS / STRUCTURAL CAE( Computer Aided Engineering)STRESS Analysis program
ADAMS CAE-Kinematics Analysis

Number & Professions of Engineers Employed

47 Mechanical Engineers
15 Industrial Engineers
8 Metallurgy Engineers
2 Agricultural Engineers
1 Electric Engineers
1 Aircraft Engineers
1 Geophysics Engineer
1 Electronics Engineer

 1 Aeronautical Engineer
1 Chemical Engineer
1 Computer Engineer
These engineers work in Process and Technology, RE-DE and
mostly in Production parts. The duties of the production team are as
follows:

Determination of the operation order

Preparation of the technical information of the operation
Preparation and publication of the operation pages
Determination of the cutting tools
Determination of operation speed and feeding values
Evaluation of the orders and stock control
Design of the molds and gages
Experimental production of the parts which will be newly produced
Preparation and trial of CNC programs
Preparation of contract and carrying out of acceptance activities of the
lathes
Preparation of settlement plans of the lathes
Manufacturing of every type of mold and gage in the tool
manufacturing workshop
The quality control of the newly arrived or manufactured cutting tools,
molds and gages
The production team is separated into 4 teams:
TEAM A
This team mainly works on the assembly line of the body and also
in the painting and distillation unit. The manager is a mechanical
engineer. One mechanical, one chemical engineer and two technicians
work in the planning and organization of the work, one metallurgical, one
chemical and two technicians work in the quality control, and finally two
mechanical and one electronics engineer work in the maintenance parts.
TEAM B
The heat treatment workshop and the gear production unit are
connected to Team B. The manager is a mechanical engineer. One
5

mechanical engineer works in the field of gears and another mechanical

engineer is his assistant, one metallurgical engineer works in heat
treatment part and another metallurgical engineer is responsible for the
laboratories. Finally one electrical engineer works in maintenance part.
TEAM C
The main work of Team C is the assembly of the gear and
transmission boxes and also production of the components that would be
used on those assembly lines. The manger is a mechanical engineer. One
mechanical engineer works in the adjustment and decrease of the
production time, another in quality control and Statistical Process
Control(SPC),the other in 5S(a special type of quality control), another
one works in the decrease of waste of cutting tools and another in
maintenance. Finally one metallurgical engineer works in planning.
TEAM D
All of the operations related to the engine including production,
testing and assembly are connected to Team D. There are three
mechanical engineers. One of them is the manager and the other two are
responsible for quality control and maintenance respectively.

Products of Trk Traktr

A) New Holland TT Series:
TT series tractors are designed for
farmers who has smaller farms and
who uses tractors mostly as industrial
or transportation usage. TT series has
4 types with different engines (50hp
55hp 60hp 65hp). Four Wheel drive is
also optional on those models. Cabin
option is only available at 60hp and
65 hp models. TT series tractors are
only sold in Turkey.
6

B) New Holland TD and Case JX Series:

TD-JX series tractors have widest
range of variations. TD series
tractors have 60hp 65hp 75hp 85hp
95hp models with lots of different
versions such as high-tire (to be
used at marshes and rice farms)
and straddle which has longer
main body. TD series tractors are
sold in Turkey and all other
countries where New Holland have
franchiser. JX series tractors are
nearly same with TD series. TD
and JX series tractors main body is
produced totally in Trk Traktr
but JX series tractors use Iveco
engines imported from Italy while engines of TD series are manufactured
and produced in Trk Traktr. Their most common difference is their
colors of course. JX series have red color which is known as Case Red
instead of blue colored New Holland Tractors. All of JX series tractors are
exported worldwide. TD and JX series tractors have lots of options such
as air condition, cabin, music system, double traction system

C) New Holland 56 Series:

55-56, 60-56, 65-56, 70-56 and 7556 are models of 56 series that are
produced in Trk Traktr. 56 series
have more classical view than
other models. They have more
cornered edges than circular. 56
series have fewer options than
other models.

Introduction
The Aim & Scope of the Summer Practice:
The aim of the summer practice program is to improve the
theoretical and the practical knowledge on production techniques and the
engineering drawing acquired in the courses just as ME113, ME114
Engineering Drawing, ME200 Mechanical Engineering Orientation and
ME202 Manufacturing Technologies. In the schedule of the
undergraduate program there exist courses on the theoretical knowledge
of Mechanical Engineering education.
The summer practice ME 300 aims for the Mechanical Engineering
students to have practical knowledge on production techniques. And it
helps to students to practice their knowledge on technical drawing and
manufacturing technologies that have gained in the courses determined
above. It suggests students to see the usage of their knowledge on
production techniques and technical drawing which learnt in previous
completed courses in the industry field and to practice them.
The summer practice for the junior year students mainly depends
on the observation and analysis of the production techniques. This
concludes that in every production unit the student should observe the
production techniques and see the use of theoretical knowledge which
acquired in school life. In industry the students have chance to see what
the people can do with the knowledge gained in school. And what is the
relation between theory and practice. So the subjects of the summer
practice are observation and analyze the production techniques used in
industry.
In the summer practice for the junior year students, students should
intensify on production. How a part is produced? After a material came to
the factory how many operations done on that material? What are these
operations? How a material controlled? How a product is controlled?
Student should try to find answer these questions.
In summer practice the aim is to learn to apply the theory on
practice. The student should try to see how an engineer, a mechanical
engineer is applying his theoretic knowledge on his job. It is very
important to see this in industry because it is impossible to learn this in
school. It can be learned only by practice and only in industry by working
in the job shop.

Report
The following most modern and various types of manufacturing
processes are being used in Turk Traktr Factory in order to achieve the
highest quality of products:

Chip Removal Processes

Cold Working Processes
Welding Processes
Heat Treatment Processes

CHIP REMOVAL (METAL CUTTING) 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 size, shape and finish. In all metal
cutting operations an edged tool is driven through material to remove
chips from the parent body and leave geometrically true surfaces. All else
that occurs merely contributes to that action. The kind of surface
produced by the operation depends on the shape of the tool and the path it
traverses through the material. Metal cutting covers the major part of the
production made in Trk Traktr. The types of metal cutting processes
used are as follows:

Turning
Drilling
Boring
Milling
Broaching
Sawing
Grinding
Honing
Lapping
Hobbing
CNC Machining

TURNING
Turning is widely used for machining external cylindrical and
conical surfaces. The workpiece rotates and a 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 get clean and flat surface. So the rough surface is
removed.
b) Cutting: If the tool is fed only towards the workpiece, that section of
workpiece 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 workpiece. Only workpiece rotates and drill
does not.
d) Boring: Lathe is used for enlarging a hole that is previously drilled.
This process is called boring.
In Trk Traktr turning is one of the most used chip removal
processes. Parts with axial symmetrical profiles are produced by turning
instead of other production techniques. Most of the turning machines are
in gear production department, also there are lathes in body production
department for shafts and axes.

DRILLING
Drilling is used for making holes or enlarging holes. The important
steps of the drilling process 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.

10

The process of drilling creates two chips. Most of the drills have
two cutting edges. The most common types of drills are twist drills. These
have the basic part s: the body, the point and the shank. The body contains
helical grooves called flutes. Larger holes in thin materials can be drilled
with a hole cutter.
When starting to drill a hole, a drill can rather deflect because of
the walking action of the point. To assure that a hole is started accurately,
a center drill and countersink is used. Because of its flexibility, a drill
may drift off centerline during drilling. The use of a center drill helps to
assure that a drill starts drilling at the desired location. If accuracy is
desired, it is necessary to follow center drilling and drilling by boring and
reaming. Boring trues the hole alignment, whereas reaming brings the
hole to accurate size and improves the surface finish.
Drilling is used widely in Trk Traktr but there are much less
drilling machines compared of parts need to be drilled. That is caused by
drilling capability 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 the shaping but milling
process is faster. Mostly the cutter rotates and workpiece is fed to a cutter.
At some milling machines, workpieces remains stationary and cutter is
fed to the workpiece. Milling process can be generated by two different
methods.
a) Up Milling: The cutter rotation is in the same direction with the feed
of the workpiece. Chip is very thin at the beginning and increases in
thickness, becoming a maximum at point where the cutter leaves the
workpiece. In up milling, chips are carried in the newly machined surface
so the surface finish is poorer than in down milling.
b) Down Milling: In down milling, maximum chip thickness occurs close
to the point where the cutter contacts the workpiece. The surface quality
of the workpiece is better than up milling because cutting process is
smoother.

11

There are generally two types of milling operations; Peripheral

Milling and 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 a versatile and a high productive process. Therefore
varieties of milling machines have been introduced. The general purpose
milling machines provide a high degree of flexibility.
Milling is the most used production technique in Trk Traktr. %80
of parts produced in Trk Traktr are at least one times milled. Because
of wide capabilities of CNC milling machines they get places of other
types of machines. Usually down milling is preferred with respect to up
milling because of higher surface quality achieved. Horizontal or vertical
milling is selected with respect to parts profile. In Trk Traktr milling
machines can be seen in all departments instead of assembly lines.

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, semifinishing 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.
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 (chip thickness). The frontal contour of the
teeth determines the shape of the resulting machined surface. As the result
of these conditions built into the tool, no complex motion of the tool
relative to the workpiece is required and the need for the highly skilled
operators is minimized.

12

Broaching usually produces better accuracy and finish than can be

obtained by milling or reaming. Mainly the relative motion between the
broaching tool and the workpiece is a simple linear motion. However a
rotational motion can be added to permit the broaching of spiral splines or
gun-barrel rifling. Broaches are commonly classified by their purpose, by
the motion of broach, construction of broach and the function of broach.
In Trk Traktr there are 4 broaching machines 3 of them are in
body production department and other is in gear production department, 2
of them are vertical broaching machine and others are horizontal
broaching machines.

SAWING
Sawing is a basic machining process in which chips are produced
by cutting the edges arranged in a narrow line. Each cutting edge called
tooth forms a chip as it passes through the workpiece. Sections of
considerable size can be reversed from the workpiece with the removal of
only a small amount of the material in the form of chips. Sawing is done
to cut the bar stock and to produce desired shapes.
All saw blades have certain common and basic features. These are
material, tooth form, tooth spacing, tooth set and blade thickness. In saw
production high-speed steel, tungsten carbide and TiN coatings are used
in order to have desired properties of saw blades.
Tooth spacing is very important in all sawing because it determines
three factors; size of teeth, the space (gullet) to contain the chip that is
formed and the number of teeth will bear against the work. Tooth set
explains the manner in which the saw blades are offset from the center
line in order to have wider cuts than the width of the saw. This permits the
saw to move more freely by decreasing the friction.

HOBBING
A hobbing machine is a special form of milling machine that cuts
gears. It is the major industrial process for cutting (as opposed to
grinding) spur gears of involute form. It forms the gear via a generating
process by rotating the gear blank and the cutter at the same time with a
fixed gearing ratio between cutter and blank.
13

The cutter has a profile given in cross section by the fundamental

rack for the gear tooth profile and is in the form of a helix so that the
sides of the teeth on the cutter generate the curve on the gear. The helix
has a number of cuts parallel to the axis to form the cutting teeth and the
profile is suitably relieved to provide cutting clearance.
Hobbing is invariably used to produce throated worm wheels. It is
not possible to cut all useful tooth profiles by hobbing; if any portion of
the hob profile is perpendicular to the axis then it will have no cutting
clearance generated by the usual backing off process and will not cut
well. The NHS Swiss tooth standards give rise to such problems. Such
small gears normally must be milled instead.
Hobbing is used in gear production department in production of all
sizes of gears.

ABRASIVE MACHINING PROCESS

Abrasive machining is the basic process in which chips are formed
by very small cutting edges that are integral parts of abrasive particles.
Grinding is the most common abrasive machining process.
Generally not suitable for bulk material removal but used for dimensional
accuracy and surface improvement by removing a small amount of
material from the workpiece surface.
Coated abrasives are use in finishing both metal and nonmetal
products. These are made by gluing abrasive grains onto a cloth or paper
backing. They are available in sheets, rolls, endless belts and disk of
various sizes. When the abrasive particles become dull, the article must
be replaced.
Honing uses fine abrasive stones to remove very small amounts of
metal. It used to size and finish bored holes, removing common errors left
by boring, or remove the tool marks (scratches) left by grinding. In
honing internal cylinders a small rotation is combined with an oscillatory
axial motion.
Superfinishing 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 the surfacefinish.

14

Lapping is an abrasive surfacefinishing process wherein fine

abrasive particles are charged into a soft material called a lap. It is a slow
metal removing process, and is used only to remove scratch marks left by
grinding or honing, or to obtain very flat and smooth surfaces.
Abrasive machining is used in production of most parts where
surface quality is important. Usually surface quality achieved by grinding
is enough but in rotating and moving parts more quality is needed; so
superfinishing or lapping applied to those parts. Honing is used in engine
production department, in production of engine blocks inside surface
where piston moves.

WELDING
In Trk Traktr 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 being joined are melted at the point where
welding occurs. Heat 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
The process is similar, but the arc is now maintained between the
workpiece and 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.
Oxyfuel Gas Cutting
All thermal cutting is done by oxyfuel gas cutting. The metal is
melted by means of the flame of the oxyfuel gas torch and then liquid
metal is expelled from the joint by the gas stream.
Resistance Spot Welding
Resistance Spot Welding (RSW) is the simplest process of
resistance welding processes. By Resistance Spot Welding processes all
of the commercial metals can be spot-welded, and most of them can be
spot-welded to each other.

15

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 foot pedal. On larger
machines or machines for larger amounts of works the electrode
movement can be obtained by an electric motor or an air cylinder.
In Trk Traktr welding is not directly used in the production of the
tractors. It is used for making palettes, work holding devicesetc, or for
repairing any kind of broken material and device or template.

TEMPERING
Steel, which has been quenched directly into the martensitic region,
is too brittle for most purpose and must be softened. Moreover,
transformations of austenite to martensite outcome high stress. 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 the material is tempered, strength and hardness decreases
but the ductility and toughness increases.
In Trk Traktr most of the raw material comes as cast, so heat
treatment is often applied before further processing. Tempering is the
most used heat treatment technique in Trk Traktr. Parts with higher
strength and hardness needed should be quenched, nitridized or induction
hardened. All of those processes make parts brittle so tempering should be
applied.

16

TECHNICAL DRAWINGS AND PRODUCTION

ANALYSIS OF SAMPLE WORKPIECES
Engineering drawing of all the parts are available at the appendix A.
Part 1
Name: 3. and 4. Speed control arm
Drawing Number / Part Number: 1.29. 008 / 598294
Material: SAE 1040 plain carbon steel
Operations Applied:
Control material
Oil quench at 870 10oC for 210 10 minutes with oil at 40-50C
inside IPSEN Cementation Furnace
Temper at 620 10C for 240 minutes
Test materials hardness (between 201-235 HRC)
Sandblast part for 10 minutes
Make all chip removal processes by CNC horizontal working
center Mazak H 630
o Side milling by tool of 40mm
o Counterbore with 20mm tool, 9mm depth
o Drill with 14,7mm twist drill
o Reamer with 15H9
o Drill 9,7mm
o Reamer drilled hole with 10mm
o Drill another hole with 5mm
Wash workpiece to clean all chips and dry with air

17

Part 2
Name: Hydraulic Lifter Cover Part
Drawing Number / Part Number: 1.82.501 / 5088960
Material: GH 190 cast iron
Operations Applied: All Operations listed are done by CNC Horizontal
milling machine Mazak H630 NX 180

Side milling with 125 mm tool

Drill with 19mm SM edged drill side to side

Enlarge drilled hole by 21.7 mm cutter

Finish hole with 22F9 reamer

Drill 6 holes with 6.8mm solid drill

Tap holes by M8 x 1.25

Chamfer edges by 1mm x 45o and 0,5mm x 45o

24mm hole drilled

Drill 8,5 mm hole

Counterbore hole with 12 mm tool

Clean part with pressurized water and dry with air

Part 3
Name: 1:2:3:4 Speed control two sided shaft
Drawing Number / Part Number: 1.29.018 / 5109831
Material: SAE 1040 Plain carbon steel
Operations Applied:
By horizontal profile milling machine Cincinatti, open 6 notches on
workpiece, two times each.
Clean chips and dry with air
Apply induction hardening with frequency 10 kHz, by CNC
induction machine FDF, until surface hardness become >52 HRC
and depth of hardened region must be between 1.70-2.20 mm
18

 Temper part at 180oC for 180 minutes

Test workpieces surface hardness, and control depth of induction
hardened region.
With CNC Hydraulic press machine Galdabini, straighten part.
Maximum straightness tolerance is 0.10
Mill one side with 222-0,05 mm dimensions using a horizontal
milling machine
Grind outer diameter to 18 H8 with centerless grinding machine
Microrex, in two passes. Cutting angle is 2o; in first pass chip
portion is 0.20mm, in second pass 0.07mm.
Wash part and dry with air
Part 4
Name: Differential locking coupling
Drawing Number/ Part Number: 1.32.608/508.88.893
Material: SAE 1040 Forged steel, mass of parts are 1.150 kg each
Cost analysis of this part is in appendix
Operations Applied:
Control part
Oil Quench 400 parts at a time, in Ipsen Cementation Furnace, at
870 10oC for 210 10 minutes. Oil temperature should not
exceed 50oC.
Temper part in cabin type tempering furnace at 55010oC for
24010 minutes. After tempering wait in room temperature to
cool.
Control hardness of parts. Hardness must be between 201-235 HB.
Because of numbers are too large only 10 parts out of 100 can be
tested

Sandblast parts for 10 minutes, 800 parts a charge.

Assembly 2 parts for a time to two headed CNC Multiplex Turning

Machine Mazak. Cut sides for 10.3450.045 mm and 6mm depth,
chamfer edges of inner surface by 2x45o.
Wash parts with pressurized water

19

 Apply gas nitriding by Aichelin Nitriding Furnace 700 parts for

charge. Surface hardness should be between 500-650 VHN and

nitride depth should be between 7-20 .

temperature C
N2 (m3/hr)
NH3 (m3/hr)
CO2 (lt/hr)
time (minutes)

step1
3505

step2 step3
5705 5705
20
1,7
2,5
125
12010 9010 15010

step4 step5
11020 11020
20
36020 10

In step 2, in last 30 minutes, N2 should be adjusted to 3m3/hr

In step 4, after temperature dropped to 110oC, N2 should be
opened 3m3/hr
Control parts surface hardness and nitride depth.
Open 8 holes to workpieces 12 R8 x 12,5
o

First drill holes with 11.7mm

Counterbore with 1,5 x 60o

Reamer with 12 mm

Wash with water to clean all chips and dry with air

20

 Strike in 8 pins with 150bar to opened holes using 25 tons

hydraulic press machine Galbadini.

21

Part 5
Name: Front axle spindle
Drawing Number/ Part Number: 1.58.206A/5088251
Material: SAE 5135 42mm Hot Rolled bar
Operations Applied:
Control part to get desired properties
Using Strip Sawing Behringer cut into 258.5 mm long pieces, 10
parts each time
Quench 27 parts in a cycle, in Stein Surface Isothermal Furnace
Temperature
(oC)

Time for one

cycle (min.)

Total Time
(min.)

Heat

88010

111*15 cycles

16514

Quench

505

51( using
Mobiltherm-R
oil)

Temper

570+20

111*20 cycles

22020

Control workpieces surface hardness, should be between 259-300

BHN. Make tests under 3000kg load with 10mm diameter steel
sphere
Sandblast parts, 216 parts for charge, for 10 minutes.
Mill both sides of workpiece and open center drill with 9 mm depth
and 10 mm maximum diameter using center and side turning
machine SICMAT
By CNC Horizontal turning machine Churchill decrease outer
diameter to 38.3mm and chamfer edges
Drill one side by 8mm and countersink edges of drilled hole.
Wash and dry with air
Apply induction hardening using CNC Induction Machine FDF.
Surface hardness 50 HRC and induction depth 1,2-1,5 mm
Temper parts at 180oC for 180 minutes in Tempering Furnace
Hedinair.

22

 Test surface hardness and control depth of induction hardened

region.
Grind outer diameter with 38.3mm to 38h7 in two cycles using
Centerless Grinding Machine Microrex.
In first cycle grind 0.25mm depth, in second cycle grind 0.06mm to
get desired output.
Part 6
Name: Differential Locking Control Fork
Drawing Number/ Part Number: 1.32.625/562073
Material: SAE 1040 Forged steel
Cost analysis of this part is in appendix
Operations Applied:
Normalize part isothermally, using isothermal annealing furnace
Stein. Normalize 81 parts at a time
Temperature
(oC)

Time for one

cycle (min.)

Total Time
(min.)

Heating

88010

101*14 cycles

13013

Tempering

60010

101*20 cycles

22020

After tempering each part should be cooled under cooling fan at least 8
minutes
Control hardness of normalized parts. Hardness should be between
165-215 HB
Sandblast parts for 10 minutes. Put 640 parts at a time.
Straighten parts. Mark straightened region by chalk.
Drill a hole with 16.5mm and mill drilled side with column type
drilling machine. Chamfer edges of drilled hole 0.8mmx45o using
hand brace.
Mill one side of workpiece in 400.2mm measurements. Open
0.8x45o countersink.

23

 Using emery stone grinding machine Quencity remove all scratches

from previous operations.
Broach part using 17 H9 broach with horizontal broaching
machine British Broaching.
Wash parts and dry
Straighten part by hand
Mill inner sides of workpiece, by centering cheeks of workpieces
with horizontal milling machine Rauchaud. In every cycle 2
workpieces can be milled. After milling clean chips produced in
this operation.
Chamfer edges of inner side of workpieces. 1.2x45o.
Apply induction hardening to cheeks of fork using CNC induction
machine FDF. Surface hardness needed 57 HRC and minimum
depth of induction hardened region is 1 mm. Because of very high
frequencies used in induction hardening (450 kHz) hardened parts
must be tempered in 3 hours after induction.
Temper parts in tempering furnace Hedinair at 180 oC for 180
minutes.
Control parts hardness and depth of induction hardened region after
tempering
Straighten part by hand, maximum tolerance of straightness
is0.05mm. Mark straightened region using chalk.
With surface grinding machine, grind outer surface in 10h11
0.110 mm. Take marked region as reference
Wash parts using pressurized water and dry

24

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. The engine lathes are used in Tool
Manufacturing Shop in the factory
Reed Prentice Engine Lathe:
Number of lathes: 6
Model: 10EE
Power: 5.58 kW
Swing over bed ways: 47 mm
Driving pulley speed: 500 rpm
Driving pulley diameter: 25.4 mm
Semi-Automatic Lathes:
There are 11 of these lathes.4 are used in Production Team B and 7 in
Team C.
Minganti Semi-Automatic Lathe:
Number of lathes: 10
Model: MINAUT 25 E, MINAUT 25
Power: 17.53 kW
Speed: 950 RPM
Max. Diameter admitted: 269.24 mm
Max. Diameter turned: 233.68 mm
Max. Turning length: 149.86 mm
Monforts Semi-Automatic Lathe:
Number of lathes: 1
Model: DA-400
Power: 19.93 kW
Max. Swing diameter over tool holder: 420 mm
Turning diameter: 400 mm

25

Normal turning length: 250 mm

Max stroke cross slides: 220 mm

Vertical Lathes:
These lathes have a rotating table. Turning, facing and drilling can also be
done on these machines. Generally used for larger workpieces. 1 of the
lathes is used in Team A, 2 in Team B and 6 is used in team C.4 of these
lathes are CNC.
Hessap CNC Vertical Lathe:
Number of lathes: 1
Model: DV 62-2 (DV-60)
Power: 130.3 kW
Swing diameter: 700 mm
Turning diameter: 650 mm
X-stroke: 600 mm
Z-stoke: 600 mm
Max. RPM: 1100
Emag CNC Vertical Lathe:
Number of lathes: 2
Model: VSC 01/500
Power: 44 kW
Max. Turning diameter: 400 mm
Max. Turning length: 250 mm
X-axis stroke: 880 mm
Z-axis stroke: 400 mm
Max. Spindle speed: 3400 rpm
Horizontal Lathes:
These lathes are used especially for machining of large workpieces like
the rear axle of the tractor. Maximum 12 tools can be mounted to the
turret. The workpiece is supported between the chuck and the center
which are controlled by 3 pedals on the floor. There are 22 horizontal
lathes in the factory. 10 of them are used in Team B, 8 in Team C and 4 in
Team D. There are also 2 thread cutting machines in the factory.
Matrix Churchill CNC Horizontal Lathe:
Number of lathes: 4
Model: CTC 4 HS X 0.5
26

Power: 28.6 kW
Max. Turning diameter: 300 mm
Z-axis stroke: 520 mm
X-axis stroke: 275 mm
Speed range: 12-4000 rpm
Mazak CNC Horizontal Lathe:
Number of lathes: 2
Model: QT-15 N-U
Power: 14.5 kW
Max. Turning diameter: 300 mm
Max. Turning length: 500 mm
Max. Swing diameter: 440 mm
Maho CNC Horizontal Lathe:
Number of lathes: 4
Model: MT 500 C
Power: 34 kW
Max. Swing over bed: 550 mm
Max. Turning diameter: 435 mm
Speed range: 20-4000 rpm

Drilling Machines
Radial Drill:
Radial drills are convenient for heavy workpieces that cannot 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. There are 36 radial drills in
the factory. 25 of them are used in Team C, 8 of them in Team A and 3 of
them in Team B.
Sass Radial Drill:
Number of machines: 19
Model: TL 1600, TL 1300
Power: 5.65 kW
Max. Drilling diameter (casting): 70 mm
Max. Drilling diameter (steel): 50 mm
Stroke: 400 mm
Spindle motors taper no: 5
Feed: 0.09-1.5 mm/giro
Stankoimport Radial Drill:
Number of machines: 6
27

Model: MOD.2A 554

Power: 6.49 kW
Drilling in steel: 50 mm
Drill in cast iron: 63 mm
Spindle end taper: no.5
RPM: 18-2000
Column Drill:
A column on a base carries a table for the workpiece and a spindle head.
There are 29 column drills in the factory.5 of them are used in Team A, 4
of them in Team B and 20 of them in Team C.
Infratirea Column Drill:
Number of machines: 10
Model: G 40
Power: 4.18 kW
Drilling diameter (steel): 40 mm
Drilling diameter (casting): 55 mm
RPM: 31.5-1400
Feed: 0.11-1.75 mm/min
Spindle stroke: 280 mm
Webo Gradua Column Drill:
Number of machines: 4
Model: VA 60
Power: 6.38 kW, 6.43 kW
Drilling diameter (steel): 60 mm
Thread cutting diameter: M45x1.5
RPM: 56-1250
Feed: 0.12-1.70 mm/min
Spindle stroke: 280 mm

Milling Machines
Horizontal Milling Machine:
This machine has a horizontal hollow spindle in the column to drive
cutters. There are 19 horizontal milling machines in the factory.3 of them
are used in Team A, which two of them is CNC, 2 of them are used in
Team B, 13 of them are used in Team C and 1 of them is used in Team D.
Cincinnati Horizontal Milling Machine:
Numbers of machines: 1
Model: Milling 2P

28

Power: 16.05 kW
Mors taper no: 50 MTS
RPM: 20-1500
Left/right motion of table: 711.2 mm
Back/front motion of table: 254 mm
Up/down motion of table: 482.6 mm
Cincinnati Horizontal Milling Machine:
Numbers of machines: 1
Model: 3P
Power: 16.05 kW
Mors taper no: 50 LTS
RPM: 18-1300
Left/right motion of table: 863.6 mm
Back/front motion of table: 304.8 mm
Up/down motion of table: 508 mm
Universal Milling Machine:
Universal milling machine is like horizontal milling machine except that
the table can be swiveled in a horizontal plane.
There are 7 universal milling machines in the factory. 1 of them is used in
Team C and 6 of them are used in Tool Manufacturing Shop.
Cincinnati Universal Milling Machine:
Numbers of machines: 1
Model: 315-154 Power
Power: 16.05 kW
Table working surface: 70.5x15
RPM: 20-2000
Vertical Milling Machine:
In vertical milling machines, the controls are similar to those of universal
model. The vertical milling machines are particularly useful in tool and
die work, where elevations, depressions, slots, etc., are called for on the
work piece. There are 9 vertical milling machines in the factory. 1 is used
in Team A, 1 in Team B and 7 of them are used in Team C
Sicmat Centering & Face milling Machine:
Numbers of machines: 2
Model: CIR 600
Power: 16.57 kW
Min. workpiece length: 50 mm
Max. Workpiece length: 600 mm
RPM: 325
Min. diameter of face milling: 20 mm
29

Max. Diameter of face milling: 100 mm

CNC Machining Centers

The most important and the major part of the mass production is made by
the CNC Horizontal Machining Centers in Turk Traktor.
There are 71 CNC horizontal machining centers in the factory. 3 of them
are used in Team A, 49 of them are used in Team C and 19 of them are
used in Team D.

Mazak CNC Horizontal Machining Center:

Numbers of machines: 3
Model: H 630
Power: 18.5 kW
Face-milling RPM: 300
End-milling RPM: 172
Drilling RPM: 110
Tapping RPM: 43
Pallet table size: 630x630 mm
Axis stroke: X-1000 mm, Y-800 mm
Mazak CNC Horizontal Machining Center:
Numbers of machines: 4
Model: H 800
Power: 18.5 kW
Face-milling RPM: 275
End-milling RPM: 180
Drilling RPM: 660
Tapping RPM: 61
Pallet table size: 800X800 mm
Axis stroke: X-1250 mm, Y-1000 mm
Mazak CNC Horizontal Machining Center:
Numbers of machines: 4
Model: H 800
Power: 18.5 kW
Face-milling RPM: 275
End-milling RPM: 180
Drilling RPM: 660
Tapping RPM: 61

30

Pallet table size: 800X800 mm

Axis stroke: X-1250 mm, Y-1000 mm

Mazak CNC Horizontal Machining Center:

Numbers of machines: 5
Model: H 1000
Power: 18.5 kW
Face-milling RPM: 350
End-milling RPM: 510
Drilling RPM: 110
Tapping RPM: 43
Pallet table size: 1000X1000 mm
Axis stroke: X-1640 mm, Y-1220 mm
Mazak CNC Horizontal Machining Center:
Numbers of machines: 17
Model: H 630 N
Power: 18.5 kW
Stroke in X direction: 1000 mm
Stroke in Y direction: 800 mm
Stroke in Z direction: 750 mm
Pallet size: 630x630 mm
Face milling RPM: 300
Mazak CNC Horizontal Machining Center:
Numbers of machines: 19
Model: H 630 NX
Power: 18.5 kW
Face-milling RPM: 300
End-milling RPM: 320
Drilling RPM: 110
Tapping RPM: 43
Pallet table size: 630x630 mm
Axis stroke: X-1000 mm, Y-800 mm
Mazak CNC Horizontal Machining Center:
Numbers of machines: 2
Model: H 415 M
Power: 7.5 kW
Axis stroke: X-560 mm, Y-510 mm, Z-510 mm
Table size: 400x400 mm
Spindle speed: 35-10000 rpm
Mazak CNC Horizontal Machining Center:
31

Numbers of machines: 13
Model: FH-680
Power: 22 kW
Face-milling RPM: 500
End-milling RPM: 410
Drilling RPM: 1065
Pallet size: 630x630 mm
X-axis motion: 1050 mm
Y-axis motion: 800 mm
Mazak CNC Horizontal Machining Center:
Numbers of machines: 1
Model: H-580
Power: 11 kW
Axis motion: X-710 mm, Y-610 mm, Z-660 mm
Pallet size: 500x500 mm
Spindle speed: 35-12000 RPM
Mazak CNC Horizontal Machining Center:
Numbers of machines: 2
Model: H-500 / 50 N
Power: 11 kW
Axis stroke: X-720 mm, Y-650 mm, Z-650 mm
Pallet size: 500x500 mm
Face-milling RPM: 338
End-milling RPM: 239
Drilling RPM: 159
Tapping RPM: 99
FLEXIBLE MANUFACTURING SYSTEM
Flexible Manufacturing Systems are the peak of automation in the
factory. These machines consist of 4 CNC horizontal machining centers
connected with a tracked rail. There are lots of pallets on the opposite side
of the machining centers and a pallet loader robot called stacker traveling
on the tracked rail. There are also 2 loading stations on which the
workpieces are mounted to the related apparatus for each new process.
The only work done by the labors is mounting the workpiece to the
apparatus before each operation on the loading station. Therefore the
system is very economical. Besides the advantages of the CNC machining
centers, time is also saved a lot due to the carriage of workpieces between
the machining centers that is done automatically. There are 4 FMS in the
factory. These systems consist of Mazak Horizontal Machining Centers

32

the models of which are H 630 NX, H-630 N/80 AND FH-680. These
systems are used for the machining of engine blocks.

More detailed information about machines used can be

found in appendix

Conclusion
The ME 300 Summer Practice Program has an important role in
mechanical engineering students life. The student studies the business
life which has to be practiced before going into that life. While examining
the techniques used in the factory, the student also faces real conditions,
real problems in that factory and applies the techniques that he/she learnt
in mechanical engineering courses. Not only developing himself in
technical manner, but he also learns the relationship between the
engineers, technicians and the workers, which is maybe much more
important in business life.
Mechanical engineers can have the opportunity to use all of their
capabilities mostly in the research and development of new projects.
Although Trk Traktr has a research and development center they can
only make some small changes on the projects due to the agreement with
New Holland. The fact that all the projects and their production methods
are received ready from New Holland leaves for the engineers only the
responsibility of controlling the production. The engineers can change the
operations in production but they cannot change the general characteristic
of the product. This makes the work monotonous for engineers. If the
dependence to New Holland could be lowered by agreements, it would be
a more exciting work for engineers.
This summer practice is definitely very useful for the mechanical
engineering students, because it is the real learning stage of the
knowledge taught to us and it is the first place that we come across with
the real work life. Trk Traktr is one of the best places for the summer
practice because it is a big company, working with a high level of
discipline and technology which are the facts that directly influence what
students gain from the summer practice.

33

APPENDIX

Technical Drawings of Workpieces

Organizational Chart
Cost Analysis
Information about Machines

34