60

60METU
E N G I N E E R I N G FA C U LT Y
M E C H A N I C A L E N G I N E E R I N G D E P T.

ME 300
S U M M E R P RA CT I CE
RE P O RT
SUMMER OF 2002

ALI GRCAN ZKL

120135-9

TA B L E O F C O N T E N T S

SECTION ONE: DESCRIPTION OF THE COMPANY

COMPANY NAME........................................................................................................................................4
COMPANY LOCATION...............................................................................................................................4
ORGANIZATIONAL STRUCTURE OF THE COMPANY......................................................................4
NUMBER AND DUTIES OF ENGINEERS EMPLOYED........................................................................5
MAIN AREA OF BUSINESS........................................................................................................................7
BRIEF HISTORY OF THE COMPANY......................................................................................................9

SECTION TWO: INTRODUCTION

AIM AND THE SCOPE OF THE SUMMER PRACTICE......................................................................16

SECTION THREE: REPORT

CLASSIFICATION AND A BRIEF DESCRIPTION OF THE PRODUCTION TECHNIQUES
EMPLOYED IN ROKETSAN....................................................................................................................17
CHIP REMOVAL PROCESSES:.......................................................................................................................17
Turning:.................................................................................................................................................19
Milling...................................................................................................................................................21
Drilling:.................................................................................................................................................22
Reaming.................................................................................................................................................23
Boring:..................................................................................................................................................24
Tapping:.................................................................................................................................................25
Thread- cutting:.....................................................................................................................................25
Sawing:..................................................................................................................................................25
Grinding:...............................................................................................................................................26
METAL FORMING PROCESSES:...................................................................................................................28
Bending..................................................................................................................................................28
Shearing:...............................................................................................................................................29
Flow forming.........................................................................................................................................30
JOINING PROCESSES:...................................................................................................................................36
Welding..................................................................................................................................................36
HEAT TREATMENT PROCESSES:...................................................................................................................38

Softening................................................................................................................................................39
Hardening:............................................................................................................................................42
Material Modification:..........................................................................................................................42
Furnaces:..............................................................................................................................................43
PRODUCTION UNITS................................................................................................................................44
LATHES........................................................................................................................................................44

CNC Lathes...........................................................................................................................................44
Universal Lathes...................................................................................................................................58
MILLING MACHINES...................................................................................................................................59
Deckel Maho DMU 125P......................................................................................................................60
Deckel Maho DMU 125T......................................................................................................................61
DRILLING MACHINES..................................................................................................................................62
FLOWFORMING MACHINE............................................................................................................................62
PRESSES......................................................................................................................................................63
FURNACES...................................................................................................................................................63
Post cure furnace...................................................................................................................................63
Insulation Bonding furnace...................................................................................................................63
PRODUCTION STAGES OF SAMPLE WORKPIECES........................................................................64
PRODUCTION OF A MOTOR CASE.................................................................................................................64
PRODUCTION OF A CONNECTOR PART.........................................................................................................64
PRODUCTION OF A AILERON.......................................................................................................................65
PRODUCTION OF A NOZZLE KERNEL...........................................................................................................65
PRODUCTION OF A MOTOR CASE(STINGER)................................................................................................66
COST ANALYSIS OF SAMPLE WORKPIECES....................................................................................67

SECTION FOUR: CONCLUSION

CONCLUSION.............................................................................................................................................69

APPENDICES
A.1
B.1
B.2
B.3
LATHE
B.4
B.5
C.1
D.1
D.2
D.3
D.4
D.5
E.1
E.2
F.1
F.2

GENERAL ORGANIZATION CHART

MANUFACTURING INFRASTRUCTURE
MECHANICAL/PLASTICAL WORKSHOP PLAN
TECHNICAL SPECIFICATION OF NILLES SIMMONS N 30
BROCHURE OF DECKEL MAHO 125 P/T
BROCHURE OF LEICO FLOWFORMING MACHINE
SPECIFICATIONS OF CUTTING TOOLS
TECHNICAL DRAWINGS OF TR-122 MOTOR CASE
TECHNICAL DRAWINGS OF CONNECTOR PART
TECHNICAL DRAWINGS OF AILERON
TECHNICAL DRAWINGS OF NOZZLE KERNEL
TECHNICAL DRAWINGS OF STINGER MOTOR CASE
COST ALLOCATION CHART
MATERIAL FLOW CHART
COST ANALYSIS OF AILERON
COST ANALYSIS OF TR-122 MOTOR CASE

SECTION 1

DESCRIPTION OF THE
C O M PA N Y
C O M PA N Y N A M E

ROKETSAN Missile Industries Incorporation

C O M PA N Y L O C AT I O N

Ankara - Samsun State Road 40th km. Elmada / ANKARA

O R G A N I Z AT I O N A L S T R U C T U R E O F T HE C OM PA N Y

The structure of ROKETSANs shareholders reflects a joint venture

type of establishment. 45% of shares are owned by Governmental
side, whereas 55% are owned by private sector. These shareholders
are: MKEK (Machinery and Chemical Industries Establishment),
ASELSAN, KUTLUTA, STFA, KALEKALIP and TSKGV (Turkish Armed
Forces Support Foundation). (Shareholders and their percentages are
given in Figure 1.1). They created a structure that successfully
combines the administrative skills of the private sector along with the
technical capabilities provided by modern technology by considering
the defense policies of the state.

Board of directions consists of representatives of the shareholders

of ROKETSANs. Monthly meetings are held to discuss company
politics and make decisions.

In ROKETSAN, board of directors gives the authority to the general

manager, who shares it with three assistant managers and four
executive directors. Each assistant general manager is responsible
from operations; financial & administrative affairs and programs &
engineering. (General organization chart is given in Appendix A.1)

Figure 1.1 Stock Share of ROKETSAN

Number and duties of engineers employed

Being a leader company in defense & aerospace sector, ROKETSAN

needs a variety of staff from different disciplines. Among 692
employees, 206 of them are engineers with variable positions. Figure
1.2 & 1.3 shows the profession distribution chart and monthly
employee distribution chart of the year 2002.

An engineer in ROKETSAN may work in mainly two areas; research

& development and production. There are different types of engineers
having specialized in different branches. These professions are;
Mechanical Eng. Chemical Eng. Aeronautical Eng. Metallurgical Eng.,
Electrical Eng., Physical Eng., Industrial Eng., Civil Eng. Branch
distribution of engineers is given in Figure 1.5

Figure 1.2 Profession Chart

Figure 1.3 Employee Distribution Chart

General
manager
Asst. Gen.
Manager
Director
Manager
Head Engineer
Chief
Specialised
Eng.

7
13
34
12
20

7
13
34
12
20

7
13
34
12
20

7
12
36
12
20

7
12
35
12
20

7
12
35
12
22

7
12
35
12
22

WHITE COLLARS (245)

JAN. FEB. MAR APR. MAY JUNE JULY

.

126
29
18

126
29
18

126
29
18

120
30
17

118
29
17

117
30
17

124
29
17

280
90
58

280
90
58

282
90
58

282
90
58

282
90
58

282
90
58

282
90
58

691

691

693

688

684

686

692

Figure1.4; Branch Distribution of Engineers

Man area of business

Establishment of ROKETSAN has aimed to accumulate an expertise

for research and development studies in the rocket and missile field.
Its main business is to provide rocket and missile requirements of
Turkish Armed Forces. On the other hand, it has become a trusted and
expert source for friendly nations collaborative NATO programs.

BLUE
COLLARS(430)

Engineer
Expert
Administrative
Staf
Technician
Support Staf
Security + Fire
Staf
TOTAL

In order to specify the main sectors of ROKETSAN, it is necessary

to look the main sectors of Turkish Defense Industry, which are
classified as follows:

Aviation and Space Industry

Rocket and Missiles Industry

Electronic Industry

Weapons and Ammunition Industry

Military shipbuilding Industry

Military Automotive and Armored Vehicle Industry

Military Clothing Industry

ROKETSAN takes place in the second one, namely Rocket and

Missiles Industry.
ROKETSAN contributes many international co-developments, joint
production programs. Some of them and their short explanations are:

ESSM

(Evolved

requirements

of

Sea

Sparrow

Turkish

Naval

Missile):

For

Forces,

ESSM

the
is

designed to intercept supersonic anti-ship missiles and

manufactured by a 10 country NATO consortium, which
is

being

NATOs

largest

cooperation.

In

the

Engineering Manufacturing and Design (EMD) phase of

the project, ROKETSAN conducted system analysis,

design

production

Replaceable

Flight

and

testing

Termination

of

26

Warhead

System

(WRFTS,

successfully.

POPEYE: Turkish Air Force has appointed ROKETSAN

to work on precision guided, air-to-ground stand-off
munitions, procured from RAFAEL-Israel. With its
experience

in

international

programs,

ROKETSAN

contributes to the POPEYE off-set program successfully.

Rapier Mk II Missiles: ROKETSAN has taken the

responsibility

of the final assembly and actuator

production in the Turkish Air force Rapier Mk II missile

program. Additionally, the actuators for Englands and
other countries Rapier Mk II missile acquisition will be
produced by ROKETSAN.

Shorad / Vshorad (Very Short Range Air Defense)

40 mm Automatic Machine Gun

122 mm Multi Barrel Rocket System with:

TR-122, 122 mm Extended Range Artillery Rocket

Family

T-122, 122 mm Multiple Launcher Rocket system

(MRS)

107 mm Multi Barrel Rocket System

B R I E F H I S T O RY O F T HE C OM PA N Y

ROKETSAN,

as

leader

in

Turkish

Defense

industry,

was

established in 1988 to help the accomplishment of national rocket and

missile technology and to serve the Turkish Armed Forces with its
modern defense products.
As

its

first

production

program,

the

company

received

responsibility in the Stinger European Co-production Program with 30

M US Dollar investment and fulfilled the liability of paying 25 M US
Dollar taxes (Figure 1.5). In parallel to the project, ROKETSAN
completed construction of Elmada facilities near Ankara and started
production in 1991.

Today, with its 600 qualified personnel,

ROKETSAN is responsible for the launcher and flight motors of

Stinger missiles and has the second largest industrial share that is
15%, among 14 leading European companies of the Consortium.
ROKETSAN is proud of being a trustable national and international
partner in Engineering and Development projects with its engineering
infrastructure and private sector dynamism.
In 1996, Extended Range Artillery Rocket TR-122 MIZRAK,
Artillery Rocket Launcher T-122 SAKARYA, and Extended Range
Artillery rocket TR-107 ANADOLU were produced and delivered to
Turkish Armed Forces as the first weapon systems in the inventory
that are completely designed, developed and manufactured by Turkish
engineers in ROKETSAN's modern facilities.

STINGER
EUROPEAN CO-PRODUCTION
PROGRAM
DORNIER

Main
contractor
Sub
contractors
GERMANY

TURKEY

HOLLAND

GREECE

DORNIER

ROKETSA
N

FOKKER

PYRKAL

BGT

ASELSAN

MEILINK

HAI

DIEHL

KALEKALI
P

COSKUNO
Z

BARIS
Figure 1.5, firms included in
program

Research and Development studies have been taking place at

ROKETSAN since its establishment.

A number of experts and

specialized engineers have been working together under a system

engineering concept, on solid composite propellant, missile design
infrastructure

development,

simulation

programs

and

advanced

composite materials, utilizing adequate testing, processing and

computer facilities.

10

ROKETSAN
organized

to

Engineering
develop

&

Development

necessary

(MU-GE)

technologies

and

Group
to

is

design

rocket/missile systems in the following expertise areas:

1) Internal Ballistics

9) Weapon systems engineering

2) Structural design

10)

Software engineering

3) Thermal design

11)

Systems engineering

4) Mechanical design

12)

Propellant technologies

5) Guidance-control

13)

Material technologies

6) Flight mechanics

14)

Composite structures

15)

Material characterization

16)

Warhead technologies

7) Operational

effectiveness

analysis
8) Aerodynamics

Turkish Ministry of National Defense has awarded ROKETSAN

Engineering and Development Department for conceptual designs.
These studies include modeling of low-level air defense systems down
to the sub-system level. A number of sub - system level simulation
tools are used for the performance prediction and analysis.
In addition to ongoing national programs, ROKETSAN participates
in the international research and development efforts within West
European Armament Group-WEAG and NATO. In WEAG, ROKETSAN
is working in Research and Technology Project RTP - 3.1 Aeronautical

11

Application Technologies and RTP - 3.4 Polymeric composites for short

range High Mach Number Missiles under CEPA-3.
In NATO, ROKETSAN is actively involved in AGARD - Propulsion
and Energetic Panel (PEP) and working in Project T - 71 within this
panel.
ROKETSAN has a modern composite propellant production line
based

On

Hydroxyl

Terminated

Polybutadiene

(HTPB).

HTPB

composite is used as the basic propellant in many rockets and missiles

where high ballistic and mechanical performance against extreme
environmental conditions is required.
A number of critical components required for rocket and missile
systems are also produced at ROKETSANs mechanical, plastic and
composite part manufacturing lines on extremely accurate numerical
control machines with reliable production techniques.
The production and insulation of motor cases, all kinds of
mechanical

and

processing

of

plastic
composite

parts

manufacturing,

materials

are

preparation

being

performed

and
at

ROKETSANs facilities.
For the requirement of TLF and TUAF, Chaff and Flare cartridges
of Counter Measure Dispenser Systems are required to be designed
and produced with high local content. With similar technology and
design capability reference, ROKETSAN is working for the in-country
production of this system.
ROKETSAN has started the design activities for a guided munitions
(PGR-Precision Guided 2.75 Rocket) as an addition to available
munitions of ATAK helicopters. This new laser guided weapon system
will use the available 2.75launcher and interfaces of the ATAK
helicopters and possess 1 m accuracy at 8 km max. range. The

12

program includes design, development, test, qualification of end

product as well as production line. After completion of the program,
the PGR will be introduced as the first product to the international
market.
For the requirement of Turkish naval forces, ESSM is designed to
intercept supersonic anti-ship missiles and manufactured y a 10
country NATO consortium. In the Engineering Manufacturing and
design phase of the project, ROKETSAN conducted system analysis,
design, production and testing of 26 Warhead Replaceable Flight
Termination System. In the production phase, ROKETSAN has the
responsibility of manufacturing several items for BAE systemsAustralia,

Honeywell-Canada,

SIGNAAL-the

Netherlands,

TDW-

Germany and TERMA-Denmark for warhead section, thrust vector

controller, and control section.
Turkish Air Force has appointed ROKETSAN to work on precision
guided, air-to-ground stand-off munitions, procured form RAFAELIsrael. ROKETSAN contributes to the POPEYE off-set program
successfully.
ROKETSAN has taken responsibility in the European Stinger CoProduction

Program

since

its

establishment.

ROKETSAN

has

completed the production of the flight and launch motors of stinger

missile successfully and scored the second largest industrial share in
the Program.
The range of 107 mm rocket has been extended to over 11 km
through a new motor designed by ROKETSAN. This achievement
provides great advantage and superiority to the artillery and the
infantry during special operations. 12 TR-107 rockets can be fired
from a towed and disassemble-and-carry type launcher that is

13

produced in turkey. As the standard warhead configu7ration 8.4 kg

HE warhead is available with this rocket. Tr-107 rockets are in serial
production for the Turkish Armed Forces since 1996.
The range of 122 mm artillery rocket has been extended to over 40
km through design and development of propulsion system and
aerodynamics. This achievement is well over the world standard and
provides great advantage and superiority to the artillery. Ripple fire of
40 rockets results to keep an area of 25 hectares under pressure.
Various warhead types in addition to 18.4 kg HE, such as steel ball
bomblets are available in accordance with customer specifications. Tr122 rocket that creates a remarkable threat over the tactical scene
can be fired from bm-21 type of launchers, as well as its original
launcher developed by ROKETSAN. Tr-122 rockets are in serial
production for the Turkish Armed Forces since 1996.
ROKETSAN has taken the responsibility of the final assembly and
actuator production in the Turkish Air force Rapier Mk II Missile
Program.

Additionally,

the

actuators

for

Englands

and

other

countries Rapier Mk II Missile acquisitions will be produced by

ROKETSAN.
40 mm Automatic Machine Gun developed recently by ROKETSAN
and KALEKALIP is an important weapon system providing antipersonnel fragmentation capability to current troops. The gun fires
the grenades such as M383 HE, m384 HE, M385 TP, M430 HEDP and
M918 (flash-bang) up to 2500 m ranges.
T-122 multiple Launcher Rocket Systems has been developed for
high performance 122 mm rockets. T-122 MRS is highly flexible,
maneuverable mobile and lethal. System consists of a 6x6 tactical
wheeled truck, fire control computer, modern communication unit,
hydraulic launcher control and power units, loading crane, automatic

14

leveling elements and launcher. The launcher having 2 pods of rockets

each carrying 20 TR-122s provides an outstanding firepower over a
large target area after a ripple fire in 80 seconds.
In parallel to the European Stinger Program and other national and
international R&D projects, ROKETSAN has a strong willingness of
using its facilities and machine shops in other defense and nondefense activities. It is a belief that the national investments reaching
50 M US Dollars, regarding the high-technology precision mechanical
manufacturing would serve as a very feasible environment for any
industry that seeks profitable co-operation in its activities. Beyond
those,

ROKETSAN

has

gained

remarkable

experience

in

international project management by involving in integrating &

producing surface-to-air precision guided munitions, anti-tank weapon
& air defense systems.
ROKETSAN design and manufacture its products and services in
accordance with national and international standards by complying
the customer requirements and expectations and deliver them in the
stated time period.
In order to improve the productivity and quality, ROKETSAN work
with the continuous improvement and do it right at the first time
principles.
ROKETSAN aims to reach their goals with consideration of
employee satisfaction by having a production system respecting
human safety and environment.

Aspects of ROKETSANs Quality system are:

15

Quality management

Calibration system as per MIL-STD-45662

Purchase control as per MIL-STD-1535

Inspections and tests at various levels

Non-conformance material control

Handling-storage-shipping control with use of special

tools,

in

environmentally

controlled

areas,

adequate documentation and shipping control

Recordings/documentation management

Internal/external vendor audits

Configuration management

Personnel training

16

with

SECTION 2

INTRODUCTION
A IM A N D T H E S C O P E O F T H E S U M M E R P R A C T IC E

The aim of the summer practice program for the junior year
students of the Mechanical Engineering Department is to reinforce
and improve the theoretical and practical knowledge on production
techniques and engineering drawing acquired in the previously
completed coursework.
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. But 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 the impossibilities on the production stage.
Thus, practical knowledge has a great importance in the education of
an engineer.
At the Mechanical Engineering Department, opportunities to give
students some practical knowledge is limited. It

is difficult to

visualize the production techniques learned in ME202 Principles of

Production Engineering. So the summer practice is a great chance for

17

students to observe various production techniques employed in

companies.
The Design made may be meaningful for the engineer, who
designed it. But in the production stage it is not meaningful. So an
engineer have to convert the design made in his mind to a shape by
which other people that are involved in production stages can easily
understand and manufacture the part. This is why technical drawing
is a fundamental part of the production. An engineer have to learn
how to make technical drawings, how to arrange these drawings and
how to read other technical drawings. Theoretical knowledge gained
in ME113/ME114 Engineering Drawing Courses should be practiced
in real life, and the summer practice is an opportunity for this aim.
In the following summer practice report, production techniques
employed in ROKETSAN, 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.

SECTION 3

REPORT

18

C L A SS I F IC AT I O N A N D A B R IE F DE S C R I P T I O N O F T H E P R O D U C T I O N
TECHNIQUES EMPLOYED IN ROKETSAN

The following various types of production techniques are being

used in ROKETSAN 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 size, shape and finish. Vast
majority of manufactured products 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. 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.
In cutting operations, there are three cutting conditions; namely
speed, feed and depth of cut. Speed (V) is the primary cutting motion,
which relates the velocity of the tool relative to work. Feed is the
amount of material removed per revolution or per pass of the tool over
work piece. The depth of cut is the depth of cutting edge engaged in
the workpiece.
The properties of the work material are important in chip
formation. High strength materials require larger forces than do

19

materials of lower strength, causing greater tool and work deflection,

increased friction and heat generation and operating temperatures,
and requiring greater work input. The structure and composition also
influence metal cutting. Hard or abrasive constituents, such as
carbides 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 longer continuous chips that remain

in contact longer with the tool face, thus causing more frictional heat.
On the other hand, some materials, such as gray cast iron, lack the
ductility

necessary

for

appreciable

plastic

chip

formation.

consequently, the compressed material ahead of the tool fails in a

brittle manner along the shear zone, producing small fragments. Such
chips are termed discontinuous or segmented.
Cutting tool materials that do not lose hardness at the high
temperatures associated with high speeds are said to have hot
hardness, but obtaining this property usually requires a trade-off in
toughness, as hardness and toughness are generally opposing
properties. In nearly all production machining operations, cutting
speed and feed are limited by the capability of the tool material. Chip
formation involves high local stresses, sliding friction and abrasion,
and considerable heat generation. The materials selected for cutting
tools must combine hardness and strength with good wear resistance
at elevated temperatures.
Metal cutting covers the major part of the production made in the
mechanical production workshop of ROKETSAN. The types of metal
cutting processes used are as follows:

20

TURNING:

Turning is a multifunctional process that is widely used for

machining internal or external cylindrical and conical surfaces.
Workpiece rotates and a longitudinally fed single point cutter removes
the inner/outer surface of the workpiece. The tools used in turning
processes are relatively simple and the workpieces machined are not
complicated. Turning operations are generally performed on a lathe.
The essential components of an engine lathe are the bed,
headstock assembly, carriage assembly, gearbox, lead screw and the
feed rod.
The bed usually is made of cast iron and provides a heavy, rigid
frame on which all the other basic components are mounted. Two sets
of parallel, longitudinal ways, inner and outer, are contained on the
bed, usually on the upper side. Some makers use an inverted V-shape
for all four ways, whereas others utilize one inverted V and one flat
way in one or both sets.
The headstock is mounted in a fixed position on the innerways,
usually at the left end of the bed. It provides a powered means of
rotating the work at various speeds. Essentially, it consists of a hollow
spindle, mounted in accurate bearings, and a set of transmission
gears through which spindle can be rotated at a number of speeds.
The spindle has a hole extending through its length, through which
long bar stock can be fed. Power is supplied to the spindle by means
of an electric motor through a V-belt or silent-chain drive.
The tailstock assembly consists of three parts. A lower casting fits
on the inner ways of the bed and can slide longitudinally. An upper
casting fits on the lower one and can be moved transversely upon it.
Third major component of the assembly, tailstock quill, is a hollow
21

steel cylinder that can be moved longitudinally in an out of the upper

casting by means of a handwheel or screw. The open end of the quill
hole terminates in a Morse taper in which a lathe center, or various
tools such as drills, can be held.
The carriage assembly provides the means for mounting and
moving cutting tools. The carriage, a relatively flat H-shaped casting,
rests and moves on the outer set of ways on the bed.
On most lathes the tool post actually is mounted on a compound
rest. This consists of a base, which is mounted on the cross slide so
that it can be pivoted about a vertical axis, and an upper casting. The
upper casting is mounted on the ways on this base so that it can be
moved back and forth and controlled by means of a short lead screw
operated by a handwheel or a calibrated dial.
The apron, attached to the front of the carriage, contains the
mechanisms and controls providing manual and powered motion for
the carriage and powered motion for the cross slide. Manual
movement of the carriage along the bed is affected by turning a
handwheel on the front of he apron, which is geared to a pinion on the
back side. This pinion engages a rack that is attached beneath the
upper front edge of the bed in an inverted position.
The size of a lathe is designated by two dimensions. The first one
is known as the swing. This is the maximum diameter of work that can
be rotated on a lathe. The second one is the maximum distance
between centers. This dimension indicates the maximum length of
workpiece that can be mounted between centers. Important things
must be considered during the turning operations such as feed rate,
rotational speed, material and geometry of the cutter. Supporting
workpieces on the lathes are also very important; the cutting forces ,
resulting from feeding the tool from right to left , should be directed

22

toward the headstock to force the workpiece against the workholder

and thus provide better work support. As there is relative motion
between the workpiece and the tool there exists large forces that can
deflect the workpiece and as the size of the workpiece increases it is
essential to use supports to avoid deflection because of the
workpieces own weight and the rotational forces. If good finish and
accurate size are desired, one or more roughing cuts usually are
followed by one or more finishing cuts. Roughing cuts may be as
heavy as proper chip thickness, tool life, lathe horsepower and the
workpiece permit. Large depths of cut and smaller feeds are preferred
to the reserve procedure, because fewer cuts are required and less
time is lost in reserving the carriage and resetting the tool for the
following cut.
If the tool is fed at an angle to the axis of rotation, an external
conical surface results. This is called taper turning. External
cylindrical, conical, and irregular surfaces can also be machined with
special cutting tools having the shape of the desired contour. This is
called form turning.

MILLING

Milling is a basic machining process by which a surface is

generated progressively by the removal of chips from a workpiece as
it is fed into a rotating cutter in a direction perpendicular to the axis
of the cutter. In some cases the work remains stationary, and the
cutter is fed to the work. It is indispensable for the manufacture of
parts of non-rotational symmetry. In nearly all cases, a multiple-teeth
cutter is used so that the material removal rate is high. Often the
desired surface is obtained in a single pass of the cutter or work and,

23

because very good surface finish can be obtained, milling is

particularly well suited to and widely used for mass-production work.
Several types of milling machines are used, ranging from relatively
simple and versatile machines that are used for general purpose
machining in job shops and tool-and-die work to highly specialized
machines for mass production. By milling more flat surfaces are
produced than by any other machining process.
The cutting tool used in milling is known as a milling cutter. It
usually consists of a cylindrical body which rotates on its axis and
contains equally spaced peripheral teeth that intermittently engage
and cut the work piece. This is called interrupted cutting.
Milling operation can be classified into two broad categories;
peripheral milling and face milling, each having many variations.
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. Both flat and formed surfaces can be
produced by this method, the cross section of the resulting surface
corresponding to the axial contour of the cutter. This process is often
called slap milling and is usually performed on horizontal spindle
machines.
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
teeth, with the face portions providing some finishing action. Face
milling is done on both horizontal-spindle and vertical-spindle
machines.
In milling, surfaces can be generated by two distinctly different
methods; up milling and down milling. Up milling is the traditional
way to mill and is called conventional milling. The cutter rotates
against the direction of the workpiece. In climb or down milling, the

24

rotation is in the same direction as the feed. The method of chip

formation is completely different in the two cases. In up milling the
chip is very thin at the beginning, and increases in thickness
becoming a 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. Because the relative motion tends to pull
the workpiece into the cutter, any possibility of looseness in the table
feed screw must be eliminated if down milling is to be used. It should
never be attempted on machines that are not designed for this type of
milling.

DRILLING:

Hole making is a very important process in manufacturing and

most of the holes are made by drilling, as a result drilling is an
important and widely used process. Although drilling appears to be
very simple, it has some difficulties. Most drilling is done with a tool
having two cutting edges. There is a friction between the body of the
drill and the wall of the workpiece, resulting in heat in addition to that
due chip formation. As a result of these conditions, substantial
difficulty can be experienced due to poor heat removal.
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 or 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 combination drill.

25

The basic work and tool motions that are required for drilling are
relative rotations between the workpiece and the tool and relative
longitudinal feeding. Basic components of a drilling machine are base,
column, powerhead, spindle and worktable. Work can be held in a jig
or fixture that is placed on the table. For too big workpieces, it can be
clamped directly to the worktable. Because of the simple work and
tool relations drilling can be done on lathes, milling machines and
some other machine tools.

REAMING

Reaming is done for two purposes: to bring holes to exact size, and
to improve the finish of an existing hole by machining a small amount
from its surface. Multi-edged cutting tools are used, and no special
machines are built especially for reaming; it is usually done on the
same machine that was employed for drilling the hole that is to be
reamed. In order to obtain proper results, only a minimum amount of
material should be left for removal by reaming.
Types of reamers
1) Hand reamers: hand reamers are intended to be turned and fed
by hand and to remove only a little metal. They have straight
shank with square tang for wrench.
2) Machine or chucking reamers: Machine or chucking reamers
are for use with various machine tools t slow speeds. they have
straight or tapered shanks and either straight or spiral flutes.
3) Shell reamers: the shell, made of tool steel and/or with carbide
edges, is held on an arbor that is made of ordinary steel. Only
shell is subjected to wear and need to be replaced when it is
worn.

26

4) Expansion reamers: Expansion reamers can be adjusted to

permit some variation in hole size to be obtained.
5) Adjustable reamers: Adjustable reamers have cutting edges in
the form of blades that are locked in a body. The blades can be
adjusted over a considerably greater range than in the case of
expansion reamers.
6) Taper reamers: Taper reamers are used for finishing holes to an
exact taper.

BORING:

Boring always involves the enlarging of an existing hole, which

may have been made by a drill or may be the result of a core in a
casting. An equally important, and concurrent, purpose of boring may
be to make the hole concentric with the axis of rotation of the
workpiece and thus correct any eccentricity that may have resulted
from the drills having drifted off the centre line. Concentricity is an
important attribute of bored holes.
Boring can be made on horizontal, vertical or angular machines as
long as the machine design provides the inherent rigidity and
accuracy to produce the tolerances required. Considerable boring is
done on the various types of lathes and also performed on some
drilling machines. Applications of boring can be divided into heavy
cutting and precision operations. Heavy boring is generally done on
large horizontal and vertical boring machines. Precision boring is
performed on machines specially designed for this purpose. These
machines

generally

take

relatively

light

cuts,

maintain

close

tolerances and often capable of high production rates. Operations

27

often performed with precision boring in the same cycle include

facing, turning and grooving. Machines are sometimes arranged for
accurate milling operations.
When boring is done in a lathe, the work usually is held in a chuck
or on a faceplate. Holes may be bored straight, tapered, or too
irregular contours. Boring is essentially internal turning while feeding
the tool parallel to the rotation axis of the workpiece.

TAPPING:

The cutting of an internal thread by means of a multiple point tool

is called thread-tapping or just tapping. A tap is a basically a
threading tool with multiple cutting teeth. Taps are generally
available with three or four flutes. The necessary hole for tapping is
generally prepared by drilling. Chip removal can be a significant
problem during tapping because of the small clearances involved. If
chips are not removed properly, the resulting excessive forces can
break the tap.

THREAD- CUTTING:

The cutting of an external thread is called thread-cutting. There

are two basic requirements for cutting thread. The first is an
accurately shaped and mounted tool, because the thread cutting is a
form-cutting operation; the resulting thread profile is determined by
the shape of the tool and its position relative to the workpiece. The
second requirement is that the tool must move longitudinally in a
specific relationship to the rotation of the workpiece, because this
determines the lead of the thread. During thread cutting process,
while the workpiece is rotating, the tool may be fed either across the

28

workpiece (radial feed), or by an angle equal to the half thread angle

measured from an axis perpendicular to tke workpiece axis (half
thread angle feed).
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 workpiece and the chip is contained within the space
between two successive teeth pass from the work. Sections of
considerable sizes can be severed from the workpiece with the
removal of only a small amount of the material in the form of chips,
sawing is probably the most economical of the basic machining
processes

with

respect

to

the

waste

of

material

and

power

consumption, and in many cases with respect to the labor.

Vast improvements have been made in saw blades and sawing
machines resulting in improved accuracy and precision of the process.
Most sawing is done to sever bar stock and shapes into desired
lengths for use in other operations: There are many cases in which
sawing is used to produce desired shapes. For producing only a few
parts contour sawing may be more economical than any other
machining process.
Saw blades are made in three basic configurations: Hacksaw blade,
Band-saw blade, Circular saw. All saw blades have certain common
and basic features. These are material, tooth form, tooth spacing,
tooth set, 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

29

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.

GRINDING:

Abrasive machining is the basic process in which chips are formed

by the small cutting edges on abrasive particles, or abrasive grits.
Abrasive machining is the oldest one of the machining processes. The
result that can be obtained by the abrasive machining range from the
finest and smoothest surfaces produced by any machining process, in
which very little material is removed, to rough, coarse surfaces that
accompany high material removal rates.
The abrasive particles may be free, coated product or bonded
product. The metal-removal process basically the same in all three
cases but with important differences due to spacing of active grains
and the rigidity and degree of fixation of the grains.
Abrasive machining processes have two unique characteristics.
First, each cutting edge is very small and many of these edges can cut
simultaneously. When suitable machines are employed, very fine cuts
are possible and fine surfaces and close dimensional control can be
obtained. Second, because very hard abrasive particles can be
produced, very hard materials can be machined.
The only natural abrasives that have commercial importance are
quartz, sand, garnets and diamonds. Quartz sand is used primarily in
coated abrasives and in air blasting, bur artificial abrasives mare also
used in these applications. Hardness is an important property for an

30

abrasive. Also two other significant properties are present for the
abrasives.
Grinding is the most common abrasive machining process. In
grinding the abrasives are bonded together into a wheel. The
performance of grinding wheels is greatly affected by the bonding
material and the spatial arrangements of the particles.
Grinding machines are classified according to the type of surface
they produce. Grinding on all machines is done in three ways. In the
first, the depth of cut is obtained by infeed-moving the wheel into the
work, or the work into the wheel. The desired surface is then
produced by traversing the wheel across the workpiece. The second
method, plunge-cut grinding, the basic movement is of the wheel
being fed radially into the work while the latter revolves on centers.
In the third method, the work is fed very slowly past the wheel and
the total depth is accomplished in a single pass.
Grinding machines have certain important characteristics that let
them to produce parts having close dimensional tolerances. They are
constructed very accurately, with heavy, rigid frames to assure
permanency of alignment. Production-type grinding machines are
more automated and have higher metal removal rates and excellent
dimensional accuracy. Fine surface finish can be obtained very
economically. The basic grinding processes are cylindrical grinding,
centerless grinding and surface grinding.

METAL FORMING PROCESSES:

31

BENDING

Bending is the plastic deformation of metals about a linear axis

with little or no change in the surface area. When multiple bends are
made simultaneously with the use of a die, the process is called
forming. The various bend axes can be at angels 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 a
simple bending theory.
Bending causes the metal on the outside to be stretched while that
on the outside is compressed. The location that is neither stretched
nor compressed is known as the neutral axis of the bend. 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 surfaces. In fact,
the neutral axis is generally located between one third and one half of
the way from the inner surface, the precise location depending upon
the bend radius and the material. Because of the preferred tensile
deformation, the metal is thinned somewhat at the bend, the thinning
being more pronounced in the center of the sheet where the material
can not freely pull in along the axis of bend.
Angle Bending: A bar folder can be used to make angles bends
up to 1500 in the sheet metal under 1.5 mm thick. The sheet of metal
is inserted under the folding leaf and moved to 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 brakes. These are mechanical or
hydraulic presses.

32

Roll Bending: Plates, sheets and rolled shapes can be bent 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 the mechanical cutting of materials without the

formation of 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.
In simple type of shearing process, as the punch descends 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 the metal, the material flows into the die
and the opposite surface bulges slightly. When the penetration
reaches about 15% to 60% of the thickness of metal, the amount
depending on the material ductility and strength , the applied
strength exceeds the shear stress and the metal suddenly shears or
ruptures through the remainder of its thickness. The two stages of

33

shearing process, deformation and fracture, can often be seen on the

edges of the sheared parts.
If the punch and die have proper clearance and are maintained in
good conditions, sheared 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 the proper
clearance and 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.

FLOW FORMING

One of the most important of production techniques in ROKETSAN

is, flow forming process. Flow forming of metal is permanent
deformation accomplished by applying mechanical forces to a metal
surface. In this process the volume and mass of metal are conserved
and the metal is displaced from one location to another. The certain
physical properties of metals are altered together with the shape and
size change during forming. Flow forming is used to reduce the wall
thickness and increase the length of tubes or performed shapes (cast,
roll formed and welled, forged, machined, pressed or spun) without
changing their inside diameter. In addition to reducing wall thickness
and increasing lengths, with resultant improvements in strength due
to plastic deformation, this process is often used to form shaped parts
from tubing or performs, such as parts with flanges and various
locations. Varying wall thickness can also be produced by employing a
tracing attachment on the machine or by using a cnc machine.

34

The flow forming technique is unmatched in its efficiency for the

chipless production of dynamically balanced hollow precision bodies.
Applicable materials are metal alloys including tempered steels and
solution heat treated aluminum alloys to be formed without chip
removal.
Advantages of flow forming:
Flow forming has many advantages. such as:

Workpiece with small shape and position tolerances

High forming degrees without heat treatment up to = 90 %

Controlled material hardening by cold forming (material

savings)

Material with tensile strengths of more than 2500 N/mm 2 can

be formed.

Excellent residual elongation values despite high forming

degrees.

Ra 0.2 inner and outer surfaces achievable.

Flow forming can be studied by approaching from two major

viewpoints, microscopic and macroscopic. Microscopic approach deals

with the physical explanation of plasticity considering the relation of
plastic behavior to the crystal structure and interatomic forces. On
the other hand, macroscopic approach is concerned more with the
relationship of plastic behavior to applied stress temperature and the
rate of deformation. These factors are particularly important in the

35

design of metal forming processes and in the design of structures and

machines.
In macroscopic sense flow forming is a method of reducing the wall
thickness of tubular shapes. Specific shapes including flanges can also
be produced at selected areas on the tube. The workpiece is deformed
between a mandrel and two or more rollers. According to the motion
direction of the roller and the material, flow forming can be described
in two forms; forward flow forming and backward flow forming.

Forward flow forming

In the forward flow the roller moves away from the fixed end of
the workpiece together with the metal. The material still to be formed
flows a head of the rollers with relatively lower speed than the roller
feed.
Advantages of forward flow forming include close control of the
lengths spun and elimination of distortion problems due to eccentric
starting tubes or preforms. The surface finish on the bore of the spun
part is almost identical to the finish on the outer surface of mandrel.
Forward flow forming is particularly advantageous when a closedend preform is being worked and the rollers can form stiffener ribs
and other forms by tracer or cnc programming.

Backward flow forming:

In the backward flow forming metals are extruded beneath the
rollers in the opposite direction of the roller feed. Preforms are not
clamped but are slid over the mandrel to the head stock at the end of
the machine.

36

Advantages of backward flow forming includes the ability to use

simpler and more economical blanks, shorter mandrels and smaller
capacity machines than required with forward flow-forming to
produce the same parts. Good diameter control can be obtained,
regardless of the tolerances on the preforms, which is a benefit in
spinning materials of limited ductility such as casting. Increased
productivity is also possible because no workpiece clamping is
required and shorter roller travel can be used to produce the same
finished length. Surface finishes as smooth as 0,20 m have been
produced with this method.
The method for the material, which will be processed, is
determinate by disadvantages between forward flow-forming and
backward flow-forming machines. Forward flow-forming has mainly
two disadvantages compared with backward flow-forming: the roller
tool must transverse the entire length of the part being formed, thus
reducing production speed and it is limited by the working stroke of
the machine.
A possible limitation of backward flow forming may be caused by
variations in the wall thickness of the preform, which results in a
proportional variation in length and some problems with straightness.
In the case of forward flow forming, in accuracies in the preform are
moved ahead of the roller and subsequently trimmed of.
There are some limitations, which affect the flow forming process.
These limitations are material limitation, preform requirements, work
hardening, formability limits and effect of machine variables.

37

Material limitation:
Any metal that is ductile enough to be formed by other methods
can be formed. The most suitable materials for flow forming have
good ductility, low hardness, high elongation, an adequate spread
between yield and ultimate strengths, a slow work hardening, and a
fine grain size.
Metals as hard a 35 HRC can be formed at the room temperature.
Some metals such as beryllium, magnesium, tungsten, most titanium
alloys and refractory alloys are preheated or heated during forming.
The heating can also be applied to compensate for insufficient
machine capacity to form thicker workpieces.
Any segregation or inclusions that exist in the material may result
in the tearing during forming. In the case of heavy reductions, even
tool marks may cause fracture.

Preform Requirements:
Preform is the name of the tube or the tubular shape before it is
formed. The preforms can be produced by deep drawing, extrusion,
casting, forging and spinning. Scale should be removed from forged or
cast preforms. Machining is preferred to obtain clean preforms.

Work Hardening:
One of the characteristics of plastic deformation of metals is the
fact that the stress required producing flow continuously increase
with increasing deformation; i.e. the material becomes more resistant
to the flow. This increase in the stress is known as strain hardening, or

38

work hardening. The irregular crystalline microstructure is changed

to a generally elongated crystalline structure where grains are
oriented with the direction of flow. If the material is annealed, the
stored energy is released and the forming operation can be continued.
The original crystalline structure is restored by the processes called
recovery and recrystallization during annealing. The heat treatment
when properly applied prevents the excessive grain growth and can
be used to refine the grain structure.

Formability Limits:
Although a theoretical approach to this problem has not been
made, empirical relations have been developed for manual spinning.
However, the maximum reduction in flow forming can be predicted
from the tensile reduction in area data.
The maximum flow forming reduction of about 80% is obtained at a
tensile reduction in area of 50%. There is no increase in formability
beyond this point.
To work harden the surface layers light deformations may be
desirable. On the other hand light reductions in area have an adverse
effect on the overall quality of the product. While the surface is
experiencing all the deformation, the bulk of the underlying material
experiences very little or no deformation. This generates a hydrostatic
tensile stress component, which can cause cracks on the mandrel side
of the tube wall. This type of fracture called by a variety of names,
such as centre burst, chevron, arrowhead and cuppy cone. To avoid
such failures in flow forming two important parameters have to be
controlled. The first one is the per pass reduction in thickness. Higher

39

reductions decrease or eliminate the fracture chance by ensuring that

the plastic deformation zone penetrates through the thickness of the
tube. The second one is the roller geometry. The deformation zone can
be enlarged by decreasing the roller angle.

Effect of machine variables:

Speeds used in practice vary widely depending on the machine
capabilities. The minimum speed is about 120 m/min. Speeds of 180360 m/min are most common. Maximum speed is not critical as long
as the adequate coolant is supplied. The feeds employed for flow
forming vary from 38 to 380 mm/min, or in terms of mm/rev feeds
vary from 0.076 to 0.20mm/rev. The use of lower feed rate has been
proven to give best results. Inside and outside diameters, as well as
wall thickness and surface finish can be controlled more accurately
when the correct speed and feed rate are employed.
Increased feed will produce a workpiece having greater wall
thickness, smaller inside diameter and rougher surface finish. The
feed and roller radius or bites are, interrelated. An increase in roller
radius results in thicker walls, larger inside diameters and finer
surface finishes. Therefore, except for the effect on wall thickness, an
increase in roller-to-workpiece contact area through the use of larger
roller radius has the same effect as a decrease in feed rate. To
maintain uniform wall thickness, the distance between the roller and
the mandrel must be decreased to compensate for the increased roller
deflection that results from increases in feed roller radius.
The other machine variable is the machine deflection and has a
direct effect on controlling the uniformity of workpiece wall thickness.

40

Deflection again can be controlled by adjusting the feed rate and

roller shape and size.

Tools for flow forming machine

1. Mandrels:
Mandrels are made from casting or by boring if they are made from
forging. Several compounds can also be put together to make
mandrels. Mandrels are usually made solid but for large sizes they are
hollow out.
Mandrel wear is a major problem. The amount of wear increases as
the strength of work metal increases or as the wall thickness of the
workpiece decreases.
Alloy cast iron hardened to about 58 HRC is often used as a
mandrel material for limited productions. The cast mandrels fail by
spalling or pitting if the application is severe. Mandrels made of steels
such as 4150 and 52100 hardened to 60 HRC have proven successful
for many forming applications. Tool steels such as D2 or D4 hardened
to 60-62 HRC have shown the best performance for rigorous service.
If the wear resistance is secondary important, to improve toughness,
mandrels made from H12 steel at 52-55 HRC can be used.
The best practice to improve the mandrel life is however to polish
mandrels lightly after every 10 to 20 workpieces.

41

2. Rollers:
Pure radius rollers are extensively used for producing large
cylindrical

components

by mainly

forward

forming.

The large

diameter permits the use of high feed rates while keeping a smooth
surface finish. However high power requirement prevents the use
light machines because of lack of adequate power and rigidity.
Tube spinning rollers are used more frequently for backward
forming and their design is similar to extrusion dies. The optimum
result is obtained when an effective bite is used. The width of the
roller land affects the surface finish. The use of shorter land rollers
produce rougher finish.
An infinite number of different reductions can be applied by the
use of staggered rollers
The lead roller takes approximately 30% of the total bite and the
second roller takes the remaining. However more power required
because more metal is deformed per unit time.
Most of the rollers are made from D2 or D4 tool steel hardened to
HRC 60. M4 tool steel at 62 HRC has also been used. Rollers made
from m42 tool steel hardened to 64-65 HRC and quadruple tempered
have given excellent wear resistance.

JOINING PROCESSES:

WELDING

Welding is a process where two materials are permanently joined

together through localized grouping, resulting from a suitable
combination of temperature, pressure and metallurgical conditions.
42

Welding can be classified in two main groups according to the

application. First one is the joining welding which joins two or more
workpieces permanently to prepare an inseparable part. In the design
of such a welding process, welding area, geometry of the meeting
parts, welding method, material and the process conditions should be
considered. The second application is called as filling welding which
fills the prescribed places with a suitable material in order to increase
the volume or to get rid of the cracks. Generally this technique is used
to repair broken or worn-out pieces. Post-weld machining or grinding
can bring the workpieces into required dimensions. In fact the
production of a quality welding requires a satisfactory heat or
pressure source, a means of protecting or cleaning the metals and
caution to avoid harmful metallurgical effects.
Gas Tungsten Arc Welding:
Gas Tungsten Arc Welding (GTAW), formerly known as Tungsten
Inert Gas (TIG) Welding, is a process that heat is obtained from an arc
between the tungsten electrode and the workpiece. Tungsten
electrode is non-consumable and filler material is supplied separately
in form of wire electrode. The tungsten electrode is held in a special
holder through which an inert gas is supplied with sufficient flow to
form an inert shield around the arc and the molten pool of metal,
thereby shielding them from the atmosphere. Argon or helium, or a
mixture of them is used as the inert shielding medium. By gas
tungsten arc welding very clean welds are produced and no special
cleaning or slag removal is required because no flux is employed.

43

Gas Metal Arc Welding:

Gas metal arc welding (GMAW), formerly known as MIG welding
(for metal inert gas), was a logical outgrowth of gas tungsten arc
welding. The process is similar, but the arc is now maintained
between the workpiece and an automatically fed, consumable wire
electrode.
Argon, helium, and mixtures of the two can be used for welding
virtually any metal; they are used primarily with the nonferrous
metals. In welding steel, some O 2 or CO2 is usually added to improve
the arc stability and reduce weld spatter. The cheaper CO 2 can be
used alone in welding steel, provided that a deoxidizing electrode wire
is employed.
The specific shielding gases can have considerable effect on the
nature of metal transfer from the electrode to the work and also affect
the heat transfer behavior, penetration, and tendency for undercutting
(weld pool extending laterally beneath the surface of the base metal).
Several types of electronic controls can be used to alter the waveform
of the current. This makes it possible to control the mechanism of
metal transfer, from drops, to spray, to short-circuiting drops. Some of
these variations

include

pulsed arc welding (GMAW-P), short-

circuiting arc welding (GMAW-S), and spray transfer welding (GMAWST). Buried arc welding (GMAW-B) is another variation in which
carbon dioxide-rich gas is used and the arc is buried in its own crater.
Gas metal arc welding is fast and economical because there is no
frequent changing of electrodes, as with stick-type electrodes. In
addition, there is no slag formed over the weld, the process can be
readily automated, and, if done manually, the welding head is
relatively light and compact. A reverse-polarity DC arc is generally
used because of its deep penetrated, spray transfer, and smooth welds

44

with good profile. Process variables include type of current, current

magnitude, shielding gas, type of metal transfer, electrode diameter,
electrode composition, electrode stickout (extension beyond the gun),
welding speed, welding voltage, and arc length.
HEAT TREATMENT PROCESSES:

Heat Treatment is the controlled heating and cooling 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 it is a very
enabling manufacturing process that can not only help other
manufacturing process, but can 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 that of any
other material.

SOFTENING

Softening is done to reduce strength or hardness, remove residual

stresses, improve toughness, restore ductility, refine grain size or
change the electromagnetic properties of the steel.
Restoring ductility or removing residual stresses is a necessary
operation when a large amount of cold working is to be performed,

45

such as in a cold-rolling operation or wiredrawing. Annealing full

Process, spheroidizing, normalizing and tempering austempering,
martempering are the principal ways by which steel is softened.

Full Annealing
Full annealing is the process of slowly raising the temperature
about 50 C above the austenitic temperature line A3 or line ACM in
the case of Hypo eutectoid steels

and 50 C into the Austenite-

Cementite region in the case of Hypereutectoid steels

It is held at this temperature for sufficient time for all the material
to transform into Austenite or Austenite-Cementite as the case may
be. It is then slowly cooled at the rate of about 20 C/hr in a furnace
to about 50 C into the Ferrite-Cementite range. At this point, it can
be cooled in room temperature air with natural convection. The grain
structure has coarse pearlite with ferrite or cementite (depending on
whether hypo or hyper eutectoid). The steel becomes soft and ductile.

Normalizing
Normalizing is the process of raising the temperature to over 60
C, above line A3 or line ACM fully into the Austenite range. It is held at
this temperature to fully convert the structure into Austenite, and
then removed form the furnace and cooled at room temperature under
natural convection. This results in a grain structure of fine Pearlite
with excess of Ferrite or Cementite. 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.

46

The main difference between full annealing and normalizing is that

fully annealed parts are uniform in softness (and machinability)
throughout the entire part; since the entire part is exposed to the
controlled furnace cooling. In the case of the normalized part,
depending on the part geometry, the cooling is non-uniform resulting
in non-uniform material properties across the part. This may not be
desirable if further machining is desired, since it makes the machining
job somewhat unpredictable. In such a case it is better to do full
annealing.

Process Annealing:
Process Annealing is used to treat work-hardened parts made out
of low-Carbon steels (< 0.25% Carbon). This allows the parts to be
soft enough to undergo further cold working without fracturing.
Process annealing is done by raising the temperature to just below the
Ferrite-Austenite region, line A1on the diagram. This temperature is
about 727 C so heating it to about 700 C should suffice. This is held
long enough to allow recrystallization of the ferrite phase, and then
cooled in still air. Since the material stays in the same phase through
out the process, the only change that occurs is the size, shape and
distribution of the grain structure. This process is cheaper than either
full annealing or normalizing since the material is not heated to a very
high temperature or cooled in a furnace.

Stress Relief Annealing:

Stress Relief Anneal is used to reduce residual stresses in large
castings, welded parts and cold-formed parts. Such parts tend to have

47

stresses due to thermal cycling or work hardening. Parts are heated to

temperatures of up to 600 - 650 C (1112 - 1202 F), and held for an
extended time (about 1 hour or more) and then slowly cooled in still
air.

Spheroidizing:
Spheroidization is an annealing process used for high carbon steels
(Carbon > 0.6%) that will be machined or cold formed subsequently.
This is done by one of the following ways:
1) Heat the part to a temperature just below the Ferrite-Austenite
line, line A1 or below the Austenite-Cementite line, essentially
below the 727 C (1340 F) line. Hold the temperature for a
prolonged time and follow by fairly slow cooling.
2) Cycle multiple times between temperatures slightly above and
slightly below the 727 C (1340 F) line, say for example
between 700 and 750 C (1292 - 1382 F), and slow cool.
3) For tool and alloy steels heat to 750 to 800 C (1382-1472 F)
and hold for several hours followed by slow cooling.

All these methods result in a structure in which all the Cementite is

in the form of small globules (spheroids) dispersed throughout the
ferrite matrix. This structure allows for improved machining in
continuous cutting operations such as lathes and screw machines.
Spheroidization also improves resistance to abrasion.

48

HARDENING:

Hardening of steels is done to increase the strength and wear

properties. One of the pre-requisites for hardening is sufficient carbon
and alloy content. If there is sufficient Carbon content then the steel
can be directly hardened. Otherwise the surface of the part has to be
Carbon

enriched

using

some

diffusion

treatment

hardening

techniques.
Hardening of steel requires a change in structure from the bodycentered cubic structure found at room temperature to the facecentered cubic structure found in the Austenitic region. The steel is
heated to Austenitic region. When suddenly quenched, the Martensite
is formed. This is a very strong and brittle structure. When slowly
quenched it would form Austenite and Pearlite which is a partly hard
and partly soft structure. When the cooling rate is extremely slow
then it would be mostly Pearlite that is extremely soft.
Usually when hot steel is quenched, most of the cooling happens at
the surface, as does the hardening. This propagates into the depth of
the material. Alloying helps in the hardening and by determining the
right alloy one can achieve the desired properties for the particular
application.
Such alloying also helps in reducing the need for a rapid quench
cooling thereby eliminate distortions and potential cracking. In
addition, thick sections can be hardened fully.

49

MATERIAL MODIFICATION:

Heat treatment is used to modify properties of materials in addition

to hardening and softening. These processes modify the behavior of
the steels in a beneficial manner to maximize service life, e.g., stress
relieving, or strength properties, e.g., cryogenic treatment, or some
other desirable properties, e.g., spring aging.

Tempering:
Tempering is a process done subsequent to quench hardening.
Quench-hardened parts are often too brittle. This brittleness is caused
by a predominance of Martensite. This brittleness is removed by
tempering. Tempering results in a desired combination of hardness,
ductility, toughness, strength, and structural stability.
Tempering is done immediately after quench hardening. When the
steel cools to about 40 C (104 F) after quenching, it is ready to be
tempered. The part is reheated to a temperature of 150 to 400 C
(302 to 752 F). In this region a softer and tougher structure Troostite
is formed. Alternatively, the steel can be heated to a temperature of
400 to 700 C (752 to 1292 F) that results in a softer structure known
as Sorbite. This has less strength than Troostite but more ductility
and toughness.
The heating for tempering is best done by immersing the parts in
oil, for tempering up to 350 C (662 F) and then heating the oil with
the parts to the appropriate temperature. Heating in a bath also
ensures that the entire part has the same temperature and will
undergo the same tempering. For temperatures above 350 C (662 F)
it is best to use a bath of nitrate salts. The salt baths can be heated up

50

to 625 C (1157 F). Regardless of the bath, gradual heating is

important to avoid cracking the steel. After reaching the desired
temperature, the parts are held at that temperature for about 2 hours,
then removed from the bath and cooled in still air.
FURNACES:

For different kinds of heat treatments, different types and sizes of

heating equipments have been developed. Furnaces can either be
batch or continuous type. Batch- type furnaces are those in which the
workpiece remains stationary inside the furnace. They can either be in
vertical or in horizontal positions. In continuous type furnaces the
workpieces are subjected to heat treatment while transferring.
Horizontal batch type furnaces are often called box furnaces
because of their shapes. A door is provided on end to permit work to
be deployed.

Usually the electric or gas energy is used as a heat

provider. They are well insulated, efficient and easy to be constructed.

However, in order not to suffer from sagging or warping in long
products vertical pit furnaces are used. The long products, or
quantities of smaller products loaded into proper baskets are lowered
into furnace through the door on the top.

PRODUCTION UNITS

In the mechanical/plastical workshop of ROKETSAN, following

units exist: a Flowforming machine, a Vertical milling machine, five
CNC milling centers, fifteen universal lathes, six CNC lathes, five
Drilling machines, three linear saws and two grinding machines.
Quantities and specifications are given in Appendix B.1

51

Manufacturing defense systems, high precision is needed in

ROKETSAN. Because of this

almost all of the machines are

numerically controlled by computers. These CNC machines allow

engineers to control small tolerances on the workpiece and maintain
high quality standards.
ROKETSAN mainly works on project basis, so location of machines
varies form project to project. This causes time loses in some cases
but

reason

for

this

problem

is

the

limited

space

in

mechanical/plastical workshop. Mechanical/plastical workshop plan is

given in Appendix B.2

LATHES

CNC LATHES

1. Niles Simmons N Series CNC Lathes

The N Series from NILES includes the complete range of CNC

slant-bed lathes. It consists of five machine sizes N 10 to N 50. The
machines are of modular construction and can be modified for
different

applications

through

the

addition

of

appropriate

attachments. The largest machine N50 has been designed for the
economic turning of components of up to one meter in turning
diameter and six meters in turning length. The machines of size N 10
and N 20 are highly efficient lathes. In ROKETSAN there is one N 21,
two N 30s, one N 32. In the other workshops other models of NilesSimmons CNC lathe exist. All these CNC lathes have 12 tool capacity
turrets.

52

a) Niles- Simmons N 21 Specifications:

Working Range
Maximum swing

520mm

above cross-slide guide

315mm

Maximum turning diameter

400mm

Turning length

2000mm

Slide travels, programmable for X-cross

300mm

Z-cross

2180mm

Working height, distance workspindle axis- foot base

1100mm

Maximum workpiece weight between centers

1000kg

in chuck only

60kg

Workspindle
Workspindle diameter in front bearing

200mm

Workspindle bore

112mm

Nominal size/ chuck

315/400mm

Maindrive
Rated motor power 100% duty cycle
Motor power 60%duty cycle

37 kW
46 kW

53

Speed range, infinitely variable speed version

10

3000 rpm

Torque
Max. torque 60% duty cycle at
workspindle without gearing

550 Nm

Max. torque 60% duty cycle with characteristic speed

725 rpm

Workspindle Indexing
Indexing

2.5 degree

Holding torque

800 Nm

C-axis
Motor power 60%/ 100% duty cycle
Speed range

8.8/7.1 kW
075 rpm

Torque 60%/ 100% duty cycle

320/260

Nm
Holding brake torque

75 Nm

Feed Drives
Feed range for X-axis (mm/min)
Z-axis (mm/min)

0.112000
0.124000

54

Rapid traverse for X-axis

12 m/min

Z-axis

24 m/min

Feed power, ax. For X-axis

6 kN

Z-axis

16kN

Tool Carrier
Number of tool pockets

12

Locating diameter

50mm

Indexing time over 1/6 positions

1.5/3.4 s

Main cutting force

12 kN

Driven Tools
Motor power 40% duty cycle

10 kW

Motor power 100% duty cycle

6.2 kW

Speed range

02320 rpm

Tailstock
Diameter of tailstock quill

155mm

Stroke rate of tailstock quill

150mm

Axial trust of tailstock quill

20 kN

55

Traversing speed of tailstock

5 m/min

Machine Dimensions
Length without swarf conveyor

4660mm

with swarf conveyor

6070mm

Width without control desk

1910mm

with control desk

Height

2865mm

2210mm

Weight without swarf conveyor

7410 kg

with swarf conveyor

7950 kg

b) Niles- Simmons N 30 Specifications:

Working Range
Maximum swing

630mm

above cross-slide guide

395mm

Maximum turning diameter

500mm

Turning length

1000mm

Slide travels, programmable for X-cross

Z-cross

370mm
1210mm

56

Working height, distance workspindle axis- foot base

1277mm
Maximum workpiece weight between centers
1800kg
in chuck only

250kg

Workspindle
Workspindle diameter in front bearing
200mm
Workspindle bore

136mm

Nominal size/ chuck

315/400mm

Maindrive
Rated motor power 100% duty cycle
Motor power 60%duty cycle

37 kW
46 kW

Speed range, infinitely variable speed version

10

2500 rpm

Torque
Max. torque 60% duty cycle at
workspindle without gearing

660 Nm

57

Max. torque 60% duty cycle with characteristic speed

600

rpm

Workspindle Indexing
Indexing

2.5

Holding torque

1000 Nm

C-axis
Motor power 60%/ 100% duty cycle

8.8/7.1

kW
Speed range

075 rpm

Torque 60%/ 100% duty cycle

400/325

Nm
Holding brake torque

90 Nm

Feed Drives
Feed range for X-axis (mm/min)
Z-axis (mm/min)

0.112000
0.124000

Rapid traverse for X-axis

12 m/min

Z-axis

24 m/min

Feed power, ax. For X-axis

6kN

Z-axis

16kN

58

Tool Carrier
Number of tool pockets

12

Locating diameter

50mm

Indexing time over 1/6 positions

1.5/3.4 s

Main cutting force

12kN

Driven Tools
Motor power 40% duty cycle

10 kW

Motor power 100% duty cycle

6.2 kW

Speed range

02320 rpm

Tailstock
Diameter of tailstock quill

155mm

Stroke rate of tailstock quill

150mm

Axial trust of tailstock quill

20kN
Traversing speed of tailstock

5 m/min

Machine Dimensions
Length without swarf conveyor

3700mm

59

with swarf conveyor

5320mm

Width without control desk

2070mm

with control desk

2700mm

Height

2500mm

Weight without swarf conveyor

7600 kg

with swarf conveyor

8500 kg

2. Churchill Series 3 CNC Lathe

Churchill lathes are especially used for longer work pieces. Similar
workpieces that are machined in Mazak or Traub are machined in
Churchill. The main difference is the dimensions of the workpieces
that are machined. The maximum diameter is 400mm and maximum
length is. Churchill CNC lathes turret can hold up to 12 tools.

Turning diameter165mm
Turning length
Speed range

290mm

60-6000 rpm

Tool numbers 12
Diameter of the tool holder

25mm

Tool dimensions 20*20 mm*mm

Rapid traverse for X and Z axes 10/10 m/min
Cutting speed 10000 mm/min

60

Motor power 75 KW

3. Traub TND200 CNC Lathe:

Traub lathe is usually used for machining nozzle elements. In this

lathe, workpieces large in diameter and small in length are machined.
Test specimens for tensile and harness tests might also be produced
in Traub. The turret can hold up to 12 tools and maximum dimensions
of the workpiece that can be machined is 350mm in diameter, 250mm
in length.

Working Capacity
Spindle capacity (max. bar diameter)
Chuck diameter

64mm
200/250mm

Swing radius over traverse slide

bed

R120mm
R240mm

Turning length

800mm

Main Drive
Three-phase AC Motor rating
with 100 (60)% duty cycle

30(35) kW

Speed range

40-4000 rpm

Range of constant rating

1:4

61

C-axis for Main Spindle

Speed

0.01-70 rpm

Torque

180 Nm

Compound Slide with Turret

Tool registers (number)

12

Slide traverses trans (x-axis)/ longitudinal (z-axis)

220/850

mm
Rapid

traverse

and

contouring

rate

X/Z

axis

(mm/min)

10000/15000
Feed thrust X/Z axis

5000/10000 N

Indexing time: 1 station/ every further station

0.7/0.27

sec

Tailstock
Quill radius

85mm

Quill stroke

140mm

Trust with 20/60 bar

3300/10000 N

Coolant Equipment
Centrifugal pump, 2 pressures-pressure
Tank capacity

1.5/5 bar
320 L

62

Machine Dimensions
Length

2955mm

Depth/height

1.99/2.05mm

4. Mazak QT15N CNC Lathe:

Mazak lathe is mainly used for machining non-metallic parts of
nozzle elements. These parts include very hard composite materials
such as graphite, feed rate and speed is lower with respect to metallic
parts machining. It has 12-tool capacity turret and up to 265mm
diameter and 500mm length workpieces can be machined with this
machine.

Capability and Capacity:

Swing on bed

R220mm

Swing on Cross-slide

R127mm

Standard machining center

R75mm

Maximum machining diameter

R210mm
Maximum machining length for shafting workpiece
451mm
Maximum machinable bar diameter
Center height on floor

50mm
1000mm

63

X-axis
Moving stroke

180mm

Rapid federate

30000

mm/min

Z-axis
Moving stroke

510mm

Rapid federate

30000

mm/min

Spindle
Spindle speed

45-4500 rpm

Number of spindle speed ranges

1 step

Pierced spindle hole radius

31mm

Turret
Number of turrets

Type of turret Dodecagonal

Number of tools mounted on the turret

12

Angular cutting tool shank height

25mm

Turret indexing time for one step (minimum)

0.48

sec
full step (minimum)
The clamping force

0.85 sec
4300 kg

64

Manual Tailstock
Tailstock moving stroke

480mm

Maximum trust of tail spindle

700 kg

Tail spindle diameter

80mm

Tail spindle moving stroke

130mm

Full Automatic Tailstock

Tailstock moving stroke

460mm

Maximum trust of tail spindle

700 kg

Tail spindle diameter

80mm

Tail spindle moving stroke

130mm

Tailstock clamping force

6800 kg

Tailstock speed

8m/min

Motors
Spindle motor (30 min/continuous)

11/15 kW

Feed axis motor for X-axis

1.0 kW

Z-axis

2.0 kW

Hydraulic motor

1.5 kW

Lubricant motor

0.003 kW

Coolant motor

0.18 kW

65

Tank Capacity
Hydraulic unit tank capacity

40 L

Lubricant tank capacity

1.8 L

Coolant tank capacity

200 L

Machine Size
Machine height

1790mm

Floor space required (with*length)

2360*2570mm
Machine weight (including the NC unit)
Shape of bed

4300 kg
Horizontal

Positioning accuracy for X-axis

0.008mm

Z-axis

0.013mm

UNIVERSAL LATHES

Universal lathes are used for rough operations, usually in first

steps of projects.

There are 12 universal lathes, which are all

numerically controlled(6 TEZSAN SN711, 1 TOS SN71B, 4 METAL, 1

AJAX). Tezsan and TOS lathes are usually

used for surface chip

removal. METAL lathes are usually used for parting operations. Ajax
lathe is usually used for machining smaller parts, with respect to the
parts machined in other lathes.
Technical Specifications of TEZSAN Lathe:

66

Total length

5000mm

Weight

3130 kg

Total width

1470mm

Total height

1440mm

The voltage of electric motor

380 V

Motor power

11/15 kW

Max. diameter of the workpiece

710mm

Turning length

3000mm

Max. longitudinal slide travel

3125mm

Maximum turning moment

24000

kg.cm
Number of minimum turning for this moment

10

rev/min
Number of maximum turning for this moment

20

rev/min
Max. weight of the workpiece for 20 rev/min

1500

kg
Coolant volume

70 L

Electric pump power

0.15 kW

Turning number of the electric pump

rev/min

67

2750

Maximum outside clamp diameter for chuck

250mm

Maximum inside clamp diameter for chuck

63mm

Diameter of the chuckhole

65mm

MILLING MACHINES

Milling machines has an important part in the production stage of

all parts in ROKETSAN. Very accurate operations are needed, because
parts machined are critical components of missile systems. There are
4 milling machines in the workshop, which are Deckel Maho DMU
125P, Deckel Maho DMU 125T, Deckel Maho MH 600E and Deckel
Maho FP2NC. 125P is 5 axis simultaneous motion milling machine
with 60 tool holding capable holder. 125T is similar to 125P except
reciprocating table, but with a special apparatus; it can be used as
3+1 axes. MH 600E(4 axes) and FP2NC(3 axes) are older machines,
which are mainly used for producing unique parts.
Brochure for Deckel Maho DMU 125 P/T milling machines is given
in Appendix B.4
DECKEL MAHO DMU 125P

Features

Standard design up to automatic 5-side machining in one

fixture

Up to 5 NC axis as standard

Universal and production-oriented options

Recirculating roller guides in all axes

68

Inherent stiffness of machine bed

Complete digital drive

Technical Data

Working Area
Longitudinal

1250mm

Vertical

880mm

Cross

800mm

Main drive
Power

15(30) kW

Speed range up to

12000

rpm
Tool mounting

SK40,

SK50
Feed range up to

15000

mm/min
Rapid traverse x, y, z axes

40

m/min

Tool magazine
Stations

30(60/120)

69

Control

MillPlus

DECKEL MAHO DMU 125T

Features

Automated single part and small series production even of

bulky workpieces

Digital drive

Recirculating roller guiding in all axis

Ultra-modern tool techniques

Technical Data

Working Area
Longitudinal

1250mm

Vertical

880mm

Cross

800mm

Main drive
Power

15 kW

Speed range up to

12000 rpm

Tool mounting

SK40, SK50

Feed range up to

15000 mm/min

Rapid traverse x, y, z axes

24 m/min

70

Tool magazine
Stations

30(60/120)

Control

Millplus

DRILLING MACHINES

Some drilling machines are used for basic hole making operations
in various type of parts in ROKETSAN. Drilling holes, increasing hole
sizes and counter sink operations are some of the machining
operations that are made in these drills. Two important drills being
used are EMI-MEC turret type drilling machine and Knuth R50 radial
type drilling machine.

FLOWFORMING MACHINE

The flow forming technique is unmatched in its efficiency or the

chipless production of dynamically balanced hollow precision bodies.
Because of this fact, flow forming process has a great importance in
ROKETSAN. Leico 3-roller flow forming machine was purchased in
1988 to produce Stinger missiles flight motor cases in accordance
with Stinger European Co-production Program. In recent years, it is
also used for producing flight motor cases of TR-122 missiles.
High accuracy is obtained by rollers that can sense the forming
forces thus optimizing the forming parameters. Using a machine
71

provided with a flow forming rollers offset by 120 o is particularly

economical for obtaining high-precise workpieces.
Brochure and technical data is given in Appendix B.5

PRESSES

Two

hydraulic

operations
COSKUNOZ

in

presses

are used for

mechanical/plastical

mainly plastical

workshop

of

parts

ROKETSAN.

hydraulic press; with 150 tons capacity and REPKON

hydraulic press; with 80 tons capacity, can be used for cold shaping
processes as well as hot working processes.
FURNACES

POST CURE FURNACE

Post cure furnace is used to perform heat treatments of tr-122

flight motor cases in different steps of production. The cases are
placed in the furnace and process temperature is achieved by an
electrical heater. Heat treatment controlling system consist of a
thermocouple, programmable controller and heater banks
The furnace has a capacity of 900 kg of steel and 200 kg of
aluminum with maximum operating temperature of 700o F

INSULATION BONDING FURNACE

Insulation

bonding

furnace

is

used

to

provide

the

proper

specifications to bond insulation to the inner surface of the tubular

case Heat treatment controlling system consist of a thermocouple,
programmable controller and heater banks

72

The furnace has a capacity of 850 kg of steel and 150 kg of

aluminum with maximum operating temperature of 5000 F.

P R O D U C T I O N S TA G E S O F S A M P L E W O R K P I E C E S

PRODUCTION OF A MOTOR CASE

Steel workpiece with 675 mm length, 140mm outer diameter and

112 mm inner diameter is placed to METAL universal lathe and its
length is decreased to 671 mm. Afterwards, outer diameter is reduced
to 138 mm, length is decreased to 668 mm and 0.7 mm chamfer
operation is done on one end in TOS SN71 Lathe. The outer diameter
is then reduced to 132 mm and length is decreased to 665 mm. Then
the workpiece is mounted to Niles-Simmons N20 lathe. Pre-installed
CNC program is run. Boring operation is done and inner radius is
increased to 118 mm. On one end 2mmx45o and on the other end
5mmx35o

counter sink operations are done. Before flow forming

process, motor cases are placed to furnaces for heat treatment.

Finally flowforming operation is done and the length is increased to
2005 mm. In turning operations, coated carbide inserts are used.
Some inserts and tools used turning and milling operations are
given in Appendix C.1
Technical drawings of the part are given in Appendix D.1

73

PRODUCTION OF A CONNECTOR PART

This steel cylindrical piece is the part, on which ailerons are

attached. Initial dimensions are 200 mm length and 170 mm diameter.
The workpiece is mounted to CURCHILL CNC lathe on which both of
ends can be machined simultaneously. First, 60 degree incline is
given to the outer surface. Then the workpiece is fixed to the chuck
from one end and the length is decreased to 180 mm. Next, the inner
diameter is increased to 90 mm. Afterwards, workpiece is mounted to
Niles Simmons N30 CNC lathe; inner radius is decreased to 100 mm
and tapping operation of M150x3 is done. Finally, other end is
mounted and eight M6x1.5 holes are drilled and tapped. In the
processes mentioned, high-speed steel inserts and coated carbide
inserts are used.

Some inserts and tools used turning and milling operations are
given in Appendix C.1
Technical drawings of the part are given in Appendix D.2

PRODUCTION OF A AILERON

The aluminum plate with dimensions 310x200x12 is mounted to

Maho Deckel DMU 125T CNC Milling machine. Because high
precision is needed in this part of the rocket, exact positioning on the
table is done and controlled by technician. Afterwards, workpiece is
machined to 307 mm in length and 197 mm in width with an end mill.
The following face milling operation reduces height to 9.5 mm. Next,
long end is machined to desired complex geometry with an end mill.
This part is machined to fit the aileron to the main body of the rocket.
And finally, workpiece mounted on special apparatus, is turned to an

74

incline to mill the other long end. This angle provides the tool holder
to mill blade part of ailerons, which should be machined very precise
in order to control high speed air flow that occurs in the flight of the
rocket. Mostly HSS inserts are used in these operations.
Some inserts and tools used turning and milling operations are
given in Appendix C.1
Technical drawings of the part are given in Appendix D.3

PRODUCTION OF A NOZZLE KERNEL

Nozzle kernel is the main part that withstands high temperature

and pressure on the rockets flight. It is made of graphite, which is
very hard but also resistible to high temperatures. TRAUB CNC
Lathes are used to machine this workpiece. Because the material to
be machines is very hard; speed, depth of cut and inserts used are
especially specified. Speed is set to 600 rpm, depth of cut is set to
0.05 mm and inserts used are Mitsubishi VCMW160408 HTI10 type.
The workpiece with initial dimensions of 85 mm outer diameter, 28
mm inner diameter and 115 mm length is mounted on to chuck. First,
length is decreased to 110 mm. Next outer diameter is decreased to
77.25 mm after a number of passes of the cutting tool. Then the
workpiece is fixed from the other end and inner diameter is increased
to 32 mm in the first 4 mm of the near end. 0.8mmx45 chamfer is
done. Finally

inner conical shape is given to the workpiece with

several passes of the cutting tool. First pass creates a rough stepped
structure and following passes cleans the inner surface and creates a
smooth conical structure.

75

Some inserts and tools used turning and milling operations are
given in Appendix C.1
Technical drawings of the part are given in Appendix D.4

PRODUCTION OF A MOTOR CASE(STINGER)

Steel preform with initial dimensions of 390mm length, 45mm

inner diameter and 68 mm outer diameter is mounted to NilesSimmons N21 CNC lathe. Its length is decreased to 370 mm. After
that, outer surface of the preform is roughly machined, inner and
outer diameters are machined to fit the flow forming machines
mandrel and motor cases are labeled. Next operation is flow forming;
preform is machined and its length is increased to 930 mm. Formed
cases are brought to furnace for heat treatment. Aim of the heat
treatment is to decrease residual stresses that might occur after
flowforming. Then motor case is mounted on to a universal lathe, both
ends are smoothed. On the lathe, upper end outer surface precise
turning operation is done and its length is decreased by cutting from
lower end. With the canal knife, locking wire canal is opened at the
lower end of the motor case. Final operation done on stinger motor
cases is thread opening. On the lower end 45 o thread is opened. HSS
inserts are used through operations.
Some inserts and tools used turning and milling operations are
given in Appendix C.1
Technical drawings of the part are given in Appendix D.5

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C O S T A N A LY S I S O F S A M P L E W O R K P I E C E S

One of the most important part of the production stage is the cost
analysis. Manufacturing of a part is meaningless for the company if its
price is lower its cost. This fact leads firms to develop some
procedures to analyze costs of parts they produced.
In ROKETSAN; a definite system is followed to calculate and
control the costs of the products. After a job is ordered, several items
are included to calculations, such as direct/indirect labor costs,
material costs, general manufacturing costs, etc. The cost allocation
chart, which explains the analysis, is given in Appendix E.1
There are two analysis methods to obtain the cost of a product;
Industrialization Cost Analysis and Serial Production Cost Analysis.
a) Industrialization Cost Analysis
Industrialization Cost Analysis is prepared before production, so
the given values are permitted to deviate. ( Usually the given values
are higher than the real values ). This cost is prepared to give the
customer a far-sightedness.
At first step unit material cost, technician cost per hour and
engineer cost per hour are calculated as a reference. Then Investment
Cost and Test Production Cost are calculated. Later these two costs
are summed to give Industrialization cost.
Material flow chart is given in Appendix E.2

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Investment Cost = (Facility Investment + Machine Investment

+ Equipment Investment)
Test Production Cost = Number of Matl. * (Technician Cost+
Eng. Cost + Material Cost{ loss percentage involved } +
Technical Drawing Preparation Cost + Tool Design Cost +
Quality

Control

Work

Cost

+Quality

Procurement

Cost

{ Validation + Pilot Batch + Reliability and Acceptance + Test

of Product ) + Project Management Cost + Travels and
Training.

b) Serial Production Cost Analysis

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Serial Production Cost Analysis is prepared after the factory

passed to the serial production. The obtained and the given values of
production cost are exact or have little chance to deviate. In fact it is
expected that the Serial Production Cost is less than industrialization
cost.
At Serial Production Cost, firstly unit material cost, technician cost
per hour and engineer cost per hour are calculated as a reference.
Then production by month, year and total production is calculated as
a reference. At the end Workmanship, Material, Depreciation, Quality
Control, Quality Procurement, Project Management Costs are summed
to give Serial Production Cost.

Serial Production Cost = Number of Matl. * (Technician Cost +

Eng. Cost + Material Cost{ loss percentage involved } +
Depreciation Cost

+ Quality Control Work Cost + Quality

Procurement Cost (Quality Management Cost + Documentation

Cost

Configuration

Management

Management Cost ).

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Cost)

Project

On the basis of Cost Allocation Chart, Material Flow Chart and the
analyses mentioned above, procedure is applied to two workpieces
that were observed in production stage, namely;

aileron and flight

motor case of TR-122 missile.

Analyses made is given in Appendix F.1 and F.2

SECTION 4

C O N C LU S I O N
During ME300 summer practice, mechanical/plastical workshop of
ROKETSAN is carefully observed from several points of views.
First of all, theoretical knowledge gained in ME202 principles of
production engineering is revised and it is combined with the
practical knowledge gained during summer practice. ROKETSAN, as a
leader company in defense industry, has some unique facilities which
contain high technology production units. The flowforming machine,
which is the only example of its kind in Turkey, CNC milling machines
which have very high initial costs and EDM machines which are not
widely used in the industry are examples for such production units.
Not only these techniques are observed, also techniques; which are
widely used in different areas of the industry are observed.

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The general location of each production unit in the workshop and

the reason of this location selection is examined. Differences,
advantages and disadvantages of non-traditional and traditional
manufacturing techniques are practiced.
Next, responsibilities of an engineer that takes part in production
stage is observed. Engineer-technician relation is seen and decisions
made by engineers in different situations is observed. The importance
of working hours and the shift system is learned.
Technical drawings are practiced. The importance of engineering
graphics is learned. The graphical representation and preparation of
the parts to be manufactured stage is observed. Computer Aided
Design systems are observed. Benefits of 3d modeling of the parts to
be produced are learned.
Research

and

development

studies

and

its

importance

for

ROKETSAN are observed. Importance of the library unit is practiced.

Opportunities of working on a project with international contributors
are seen. Importance of international projects for ROKETSAN and for
Turkish defense industry is learned.
General safety rules of the company are learned. Importance of the
safety restrictions obeyed in a factory that contains highly explosive
materials is carefully understood.
To conclude, summer practice is an opportunity for prospective
engineers to learn the realities of the life, which can not be taught at
school.

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