staj defteri
TRANSCRIPT
DESCRIPTION OF THE COMPANY
The name of the company
TEMSAN
Turkish Electromechanics Industry (Circuit brakers&disconnectors Factory)
The location of the company
Bağdat Caddesi, Ostim yolu 06370
Macunköy, Ankara
Phone: 0312 397 55 75 (8 Lines)
Web: www.temsan.gov.tr
E-mail: [email protected]
Plant Area
Total closed area: 98.349 m2
Total area: 25.889 m2
Organization structure of the company
+ Organization structure of the company is given in Appendix A
Number and duties of engineers employed
16 engineers are employed in company:
+ 8 Mechanical Engineers
+ 4 Electronic Engineers
+ 3 Electric Engineers
+ 1 Industrial Engineer
1
Duties of Department of Manufacturing Engineering
Determination of the location in the factory where operations will take place
Designation of the cutting tools
Design of the necessary fixing tools and supports
Measuring and checking process times
Investigation of the production capacities of the machines
Deciding on how products will be produced according to the technical drawing
Preparing follow-up and operation files which show the production steps of a work
piece
Duties of the Department of Assembly Engineering
To follow new technologies
Making arrangements for the equipment supplement
Organize the mechanical production and be responsible from the assembly lines
To control production and manufacturing and solving the problems during the
assembly
Duties of the Department of the Re & De Engineering
Design and development of new products
Redesign and development of new products when error occur after sale
Computer aided design (2D and 3D)
Transmission testing
Engine testing
Duties of the Engineers at Assistance Service Area
Education of the operators in order to increase the quality and productivity
Planning of the heat treatment, dyeing, covering machines and operators in order to
increase productivity
2
Duties of Engineers at Quality Assurance Department
Preparing the list of the cost of the materials
Testing the machines whether they are made properly or not
Determining the policy and aims of the company and find out the standards to be
followed
Providing continuity of the production quality
Main area of the company
The company is aimed at installing, operating, rehabilitating hydro electric power plant
by realizing investment, production and erection works related with the switch equipment,
power transformers turbo and hydro generators, hydro turbines used for the electrical energy
generation and distribution
The mission of the TEMSAN is to increase the electrical energy generation which is the
indication of the civilization and comfort, to get additional value by this generation and to
increase the electrical equipment production; indicating knowledge, skill and technological
power.
TEMSAN, Turkish Electromechanics Industry studies on two different areas generally.
In Diyarbakir (Hydraulic Turbine and Generator Factory) and in Ankara (High Voltage and
Medium Voltage Circuit Breakers and Disconnections Factory – OYKAF-), the company is
making production.
In the part of the company which is situated in Ankara, some sort of circuit breakers and
disconnectors are produced. These products are:
Medium and High voltages, vacuum packed and SF6 gas filled breakers
Command and relay panels
Metal clad cubicles for the hydro electric power plants
Step down transformer substations
Control command, measuring and protection systems for the hydro electric power
plants
3
The products leave the factory after production processes. Some parts of these products
are sold to some sort of factories or service areas, and other parts are purchased by some
electrical companies and used all over the Turkey.
There are approximately 2000-3000 components in the structure of the circuit breakers
and disconnectors. Most of these components are produced in Ankara factory, but the
components which are found as “standard” are purchased from the industry.
In Diyarbakir Factories:
Hydro electric turbine
Butterfly vane
Draft tube (cone and connection element)
Turbine head covers and rings
Speed governors and tanks
Turbine pit liners are produced.
A brief history of the company
TEMSAN is the first and unique Turkish Company with a successful past of 32 years in
the sector of production, establishment, operation and maintenance service of energy
installations with the two factories in Ankara and Diyarbakir.
TEMSAN started its production at 09.02.1977 in Diyarbakir. The constitutive-
associations of the company are:
TEAŞ – Turkiye Elektrik Üretim İletişim A.Ş.
Türkiye Kalkınma Bankası A.Ş.
Makina ve Kimya Endüstri Kurumu
Turkiye Seker Fabrikaları A.Ş.
Turkiye Vakıflar Bankasi A.O.
4
In 1984, Ankara Factory of TEMSAN has been established by German Siemens
Company, and then in 1987 factories has started to continue production as a foundation of
İller Bank. As a result, in 1994 these factories have been purchased by TEMSAN.
The company has been established as a joint-stock company and listed in the Ankara
Trade Association with the 34690 register number.
The production capacity of the Ankara M.V and H.V circuit breakers and disconnectors
factory is 4200 M.V circuit breakers a year or equivalence product to this quantity.
In TEMSAN A.Ş. M.V and H.V circuit breakers and disconnectors Factory; planning,
projecting, researching, developing, purchasing, and service labor are performed and these
are suitable for TS-ISO 900 standards.
INTRODUCTION
Subject
The subject is to examine the production and production techniques.
Aim
The aim of the ME 300 summer program for the junior year students of Mechanical
Engineering Department is to improve the theoretical and practical knowledge on production
techniques and engineering drawing acquired in the previously completed course work (ME
113, ME114, and ME 202)
Theoretical knowledge is very important at the engineering part of a product. The
engineer must know the criteria for the proper design of the product. However, theoretical
knowledge alone is not sufficient to manufacture a product. Some perfect designs might be
developed with only theoretical knowledge, but such designs might not be manufactured
5
because of some impossibities. Therefore, practical knowledge has a great importance in the
education of an engineer.
In the Mechanical Engineering Department opportunities to give students some practical
knowledge is limited. It is difficult to understand the production techniques learned in me
202. Thus, the summer practice is a great chance for students to observe various production
techniques employed in companies.
Also, an engineer have to learn how to make technical drawings, how to arrange these
drawing and how to read other’s technical drawings. Theoretical knowledge gained in ME
113 and ME 114 should be practiced in real life and summer practice is an opportunity for
this aim.
In the following summer practice report, production techniques employed in TEMSAN,
machines and their uses in the organization, technical drawings are examined and production
and cost analysis of sample pieces observed are cited and explained in detail.
6
REPORT
The following various types of production techniques are being used in TEMSAN in
order to achieve the highest quality of products.
CHIP REMOVAL PROCESSES
Metal cutting, commonly called machining, is the removal of unwanted portions from a
block of material in the form of chips so as to obtain a finished product of desired shape, size
and finish. Vast majority of manufactured product require machining at some stage in their
production, ranging from relatively rough work to high precision work. Thus, metal cutting
is the most important of the basic manufacturing processes.
In all metal cutting operations an edged tool is driven through material to remove chips
from the parent body and leave geometrically true surfaces. The kind of surface produced by
the operation depends on the shape of the tool and the path it traverses through the material.
The properties of the work material are important in chip formation. High strength
materials require larger forces than do materials of lower strength, causing greater tool and
work deflection, increased friction and heat generation and operating temperatures, and s
requiring greater work input. The structure and composition also influence metal cutting.
Hard or abrasive constituent, such as carbide in steel, accelerate tool wear.
Work material ductility is an important factor. Highly ductile materials not only permit
extensive plastic deformation of the chip during cutting, which increases work, heat
generation, and temperature, but it also results in larger continuous chips that remain in
contact longer with the tool face, thus causing such as gray cast iron, lack the ductility
necessary for appreciable plastic chip formation. Consequently, the compressed material
ahead of the tool fails in brittle manner along the shear zone, producing small fragments.
Such chips are termed continuous or segmented.
7
Metal cutting covers the major parts of the production made in the mechanical
production of TEMSAN. The types of metal cutting processes used are as follows:
Turning
Drilling
Milling
Broaching
Grinding
Lapping
Honing
Sawing
CNC Machining
Turning
Turning widely used for machining external cylindrical and conical surfaces. The work
piece rotates and longitudinally fed single point cutter does the cutting. External cylindrical,
conical and irregular surfaces of limited length can also be turned by using a tool having a
specific shape and feeding it inward against the work. The shape of the resulting surface is
determined by the shape and size of the cutting tool. Machine tools used for this process are
called lathes.
Besides turning, lathes are capable of performing a variety of processes as given below.
a) Facing: Cutting tool must be fed towards only surface of the work piece in order to
set clean and flat surfaces. Thus, the rough surface is removed.
b) Cutting: If the tool is fed only towards the work piece, that section of work piece is
cut along the position of tool.
c) Drilling: Drilling on lathes is done with the drill that is in the tailstock. Tailstock fed
by hand against work piece. Only work piece rotates and drill does not.
d) Boring: Lathes is used for enlarging a hole that is previously drilled. This process is
called boring.
8
In TEMSAN A.Ş. chip removal processes are the most used processes. Parts with axial
symmetric profiles and most of the circuit breakers and disconnectors are produced by
turning operations.
Drilling
Drilling is used for making holes or enlarging holes. The important steps of the drilling
processes are; firstly the upper point of the drill forms very small hall. As the drill goes
through against the material, chips start to form. Then chips are removed from the hole by
means of special shapes of drills. Because of friction between material and drill, temperature
may get undesired values. Lubrication fluid can be used in order to decrease the temperature.
Drills are of six types. The most common types of drills are twist drills. These have three
basic parts; the body, the point and the shank. The body contains two ore more spiral grooves
called flutes in the form of a helix. The flutes serve as channels through which the chips
come out of the hole and permit coolant to get to the cutting edges. Other types of drills are
deep hole drills, trepanning cutters, center drills, countersinks, spade drills and special
combinations drills.
Basic components of drilling machines are; base, column, power head, spindle and
worktable. Work can be held in a jig or fixture that is placed on the table. For too big work
pieces, it can be clamped directly the worktable.
Drilling is used widely in TEMSAN, but there are much less drilling machines compared
parts need to be drilled, because of the drilling capacity of lathes and milling machines.
MILLING
In this process, multiple-tooth cutter is used so that cheap removal rate is very high. Its
job is mainly same with shaping but milling process is faster. Mostly the cutter rotates and
work piece is fed to a cutter. At some milling machines, work pieces remain stationary and
cutter is fed to the work piece. Milling processes can be generated by two different methods.
9
Up milling is the traditional method and it called conventional milling. The cutter rotates
against the direction of the work pieces. In climb or down milling, the rotation is the same
direction as the feed. The method of chip formation is completely different in two cases. In
up milling, the chip is very thin at the beginning, and increases in thickness become
maximum where the tooth leaves the work. In down milling, maximum chip thickness occurs
close to the point at which the tooth contacts the work. The surface quality of the work piece
is better than up milling because cutting process is smoother.
There are generally two types of milling operations:
Peripheral milling
Face milling
In peripheral milling the surface is generated by teeth located on the periphery of the
cutter body. The surface is parallel with the axis of rotation of the cutter. In the face milling,
the generated surface is at right angles to the cutter axis. Most of the cutting is done by the
peripheral portions of the cutter teeth.
Milling is one of the most used production techniques in TEMSAN. Especially down
milling is preferred with respect to up milling because of the higher surface quality.
Horizontal or vertical milling is selected depending on the parts of circuit breakers or
disconnectors.
Broaching
Broaching is a unique machining process in which chips are removed by a number of
successive teeth increasing in size, built on a long tool named broach. Roughing, semi
finishing, and finishing teeth, consequently the related processes are combined in a single
tool. The profile of the machined surface is the inverse of the profile of the broach. The
cutting action is performed in a fixed path, and with one stroke of the broach, the process is
completed. Broaching is suitable for mass production where the high production rate justifies
the cost of the expensive tool.
10
A broach is composed of a series of teeth, each standing slightly higher than the last.
This rise per tooth, also known as step, determines the depth of cut by each tooth. The frontal
contour of the teeth determines the shape of the resulting surface. As the result of these
conditions built into the tool, no complex motion of the tool relative to the work piece is
required and the need for the highly skilled operators is minimized.
Grinding
Grinding is a process which moves relative a surface in a plane while a grinding wheel
contacts the surface and removes material, such that a flat surface is created. Produce a very
flat surface, very accurate thickness tolerance and cutting tool sharpening are some of the
reasons of grinding.
Honing
Honing uses fine abrasives stones to remove very small amount of metal. It used to size
and finished bored holes; removing common errors left by boring, or remove the tool marks
left by grinding. In honing internal cylinders a small rotation is combined with an oscillatory
axial motion.
Also, super finishing is a variation of honing which results in surfaces of very uniform,
repeatable smoothness. It is not a process of changing dimensions, but only improves surface
finish.
Lapping
Lapping is an abrasive surface finishing process where in fine abrasives particles are
charge into a soft material called a lap. It is a slow metal removing processes, and is used
only to remove scratch marks left by grinding or honing or to obtain very flat and smooth
surfaces.
11
Abrasive machining (grinding, honing, and lapping) is used in production of most parts
where surface quality is important in TEMSAN. Usually surface quality achieved by
grinding is enough but in rotating and moving parts more quality is needed; so super
finishing or lapping are applied to those parts.
Sawing
Sawing is a basic machining process in which chips are produced by a succession of
small cutting edges or teeth, arranged in a narrow line on a saw blade. Each tooth forms a
chip progressively as it passes through the work piece and the chip is contained within the
space between two successive teeth pass from the work.
Sections of considerable size can be severed from the work piece with the removal of
only a small amount of the material in the form of chips. Sawing is the most probably the
most economical of the basic machining processes with respect to the vast of material and
power consumption, and in many cases with respect tot the labor.
CNC Machining
Numerical control is a method of controlling the motion of machine components by
means of numbers or coded instructions. When the data handling, control sequences and
response to input is determined by the microprocessors it is called CNC. This system
includes preconception, planning and coding of all necessary machine motions and functions
by a programmer followed by a transmission of these instructions to the machine control,
which activates machine functions.
12
JOINING PROCESSES
WELDING
In TEMSAN the applied methods of welding are as follows:
Arc Metal Welding
The arc is struck with no additional shield gas supply, between the consumable
electrode fed from the coil and the work. The electrode also acts as a filter. The metals are
being joined are melted at the points where welding occurs.
Head is obtained by an arc between the work and the electrode. Composition of the
consumed materials and weld quality depends on the skill of the operator.
Gas Metal Arc Welding (GMAW)
The process is similar but the arc is now maintained between the work piece and the
wire electrode. The consumable wire electrode provides the filter metal. An inert gas is
supplied with sufficient flow to form an invert shield around the arc and the molten pool of
metal, therefore shielding them from the atmosphere.
Oxy-fuel Gas Cutting
All thermal cutting is done by oxy-fuel cutting. The metal is melted by means of the
flame of the oxy-fuel gas torch and then liquid metal is expelled from the joint by the gas
stream.
Resistance Spot Welding (RSW)
Resistance spot welding is the simplest process of the resistance welding processes. By
this process, all of the commercial metals can be spot welded to each other.
13
If proper current and timing, electrode shape, electrode pressure and surface conditions
are maintained, spot welds can be obtained with excellent quality. There are several types of
spot welding machines. For light production work the simple rocker-arm machine is used. At
this machine the upper electrode is moved by means of a food pedal. On larger machines or
machines for larger amounts of work , the electrode movement can be obtained by an electric
motor or an air cylinder.
In TEMSAN, welding is used for joining the components of circuit breakers and
disconnectors or for repairing any kind of broken material and device.
HEAT TREATMENT PROCESSES
Heat treatment is the controlled cooling and heating of metals to alter their physical and
mechanical properties without changing the product shape. Heat treatment is sometimes done
inadvertently due to manufacturing processes that either heat or cool the metal such as
welding or forming. It is often associated with increasing the strength of material, but it can
also be used to alter certain manufacturability objectives such as improve machining,
improve formability, and restore ductility after a cold working operation. Thus, that is very
enabling manufacturing process that can not only help other manufacturing processes but
also improve product performance by increasing strength or other desirable characteristics.
Steels are particularly suitable for heat treatment, since they respond well to heat treatment
and the commercial use of steels exceeds of any other material.
In TEMSAN, nowadays, the heat treatment department is not very active, but some row
materials comes as cast, so some of the heat treatment processes such as tempering and
normalizing are applied before further processing.
14
Tempering
Steel, which has been quenched directly into the martensitic region, is too brittle for
most purpose and must be softened. Moreover, transformation of austenite to martensite
outcome high stresses. Therefore, tempering which solves the brittleness problem and gives
the material a full structure is applied. Martensite is strong and hard but relatively brittle.
When material is tempered, strength and hardness decreases, but the ductility and toughness
increases.
Normalizing
Normalizing is the process of raising the temperature to over into the austenite range. It
is held at this temperature to fully convert the structure into austenite, and then removed
from the furnace and cooled at room temperature under natural convection. This results in a
given structure of fine pearlite with access of ferrite or cementide. The resulting material is
soft; the degree of softness depends on the actual ambient conditions of cooling.
This process is considerably cheaper than full annealing, since there is not the added cost
of controlled furnace cooling.
METAL FORMING PROCESSES
BENDING
Bending is the plastic deformation of the metals about a linear axis with little or no
change in the surface area by stressing the metal above its yield strength but not larger than
its ultimate tensile strength. When multiple bends are made simultaneously with the use of a
die, the process is sometimes called forming. Plastic bending differs form elastic, reversible
bending in that the bend radius must be small enough to bring much of the sheet cross
section into the state of plastic flow. The various bend axes can be at angles to each other,
but each axis must be linear and independent of the others for the process to be classified as a
true bending operation and be treatable by simple bending theory. If the axes of deformation
15
are not linear or not independent, the process becomes one of drawing or stretching not
bending. Characteristic of this process is stretching imposed at the outer surface and
compression on the inner surface. Since the yield strength of metals in compression is
somewhat higher than the yield strength in tension, the metal on the outer side yields first,
and the neutral axis is displaced from the center of the two surfaces. Because of the preferred
tensile deformation, the metal is thinned somewhat at the bend, thinning being pronounced in
the center of the sheet where the material can not freely pull in along the axis of the bend.
a) Angle Bending: A bar folder can be used to make angles bends up to 1500 in the
sheet metal fewer than 1.5 millimeters thick. The sheet of metal is inserted under the
folding leaf and moved the proper position. Raising the handle actuates a cam
causing the leaf to clamp the sheet. Further motion of the handle, bends the metal to
the desired angle. Bar folders are manually operated and are usually less than 4
meters long. Bends in heavier sheet or more complex bends in thin material are
generally made on press breakers. These are mechanical or hydraulic presses.
b) Roll Bending: Plates, sheets and rolled shapes can be bended to a desired curvature
on forming rolls. These machines usually have three rolls in the form of a pyramid,
with the lower rolls being driven and the position of the upper roll being adjustable
to control the degree of curvature. When the rolls are supported by a frame on each
end, one of the supports can often be swung clear to permit the removal of closed
shapes from the rolls. Roll bending machines are available in a wide range of sizes,
some being capable of bending plate up to 150 mm thick.
SHEARING
Shearing is mechanical cutting of materials without the formation of the chips or the
use of burning or melting. When the two cutting blades are straight, the process is called
shearing. When the blade geometry is curved, as in the edges of punches and dies, the
process has special names, such as blanking, piercing, notching, shaving and trimming.
16
In the simple type of shearing processes, as the punches descend against the work piece,
the metal is first deformed plastically into the die. Because the clearance between the two
tools is only 5% to 10% of the thickness of the metal being cut, the deformation is highly
localized. The punch penetrates into metal, the material flows into the die and the opposite
surface bulges slightly. When the penetrations reaches about 15% to 60% of the thickness of
the metal, the amount depending on the material ductility and strength, the applied strength
exceeds the shear stress and the metals suddenly shears or ruptures through the reminder of
its thickness. The two stages of shearing processes; deformation and fracture can often be
seen on the edges of sheared parts.
If the punch and die have proper clearance are maintained in good conditions, shared
edges may be produced that are sufficiently smooth to use without further finishing. The
quality of the shear can be further improved if the strip stock is clamped firmly against the
die from above; the punch and die are maintained with proper clearance alignment and the
movement of the piece through the die is restrained with an opposing plunger or rubber die
cushion applying pressure from below the work piece. These measures cause the shearing to
take place uniformly around the edge rather than randomly at the weakest points.
FORGING
Forging is the process in which metal, cold or heated, is shaped into component
geometry through the use of multiple blows with a drop hammer or through the application
of pressure with a hydraulic press. For most forging processes, a set of dies are required.
Due to grain orientation, forgings are a desirable choice when high strength and excellent
fatigue life is required for the component. Many materials can be forged including
aluminum and steel.
17
INFORMATION ABOUT MACHINES USED
Engine Lathes
These are heavy duty machine tools which have power drive for all tool movements
except on the compound rest. They have chip pans and a built in coolant circulating system.
Engine lathes are used for rough operations, usually in first steps of projects. There are 5
universal lathes.
TEZSAN Universal Lathes
Number of machines: 5
Model: SN 50
Total Length: 3575mm
Weight: 1815kg
Total Width: 2000mm
Total Height: 1150mm
The Voltage of electric motor: 380V
Motor Power: 5.5/7.5 kW/HP
Max Diameter of work piece: 500mm
Turning Length: 2000mm
Coolant Volume: 45L
Electric Pump Power: 0.15 kW
Diameter of Chuck Hole: 65mm
Semi-Automatics Lathes
There are 14 of these lathes in manufacturing shop of the factory to manufacture circuit
breakers and disconnectors’ parts.
18
MONFORTS Semi-Automatics Lathes
Number of machines: 5
Model: FAR 1042
Power: 11 kW
Turning diameter: 340 mm
Normal turning length: 150mm
Max stroke cross slides: 115 mm
INDEX Semi-Automatics Lathes
Number of machines: 9
Model: ER 42
Max diameter admitted: 220 mm
Max diameter treating: M30
Max broaching depth: 110 mm
Max turning angle: +15, -30
Milling Machines
Milling machines has an important role in the production stage of all parts in TEMSAN.
Very accurate operations are needed because parts machined are critical components of circuit
breakers and disconnectors.
Horizontal Milling Machines
These machines have a horizontal hollow spindle in the column to drive cutters. There are
3 horizontal milling machines in the machine shop of the factory.
FRITS WERNER Horizontal Milling Machines
Number of machines: 3
Model: HF 3
Power: 11 kW, 15 HP
Min-Max RPM: 35.5 – 1800
19
X – Y- Z axis format: 1200- 310- 400 mm
Max mandrel diameters: 27 mm
Mandrel Conicity: DIN 2080
Universal Milling Machines
Universal milling machines are like horizontal milling machines except that the table can
be swiveled in a horizontal plane.
There are 5 universal milling machines in the factory to manufacture circuit breakers and
disconnectors parts.
DECKEL Universal Milling Machines
Number of machines: 5
Model: FP 346
Power: 4 kW / 5.4 HP
X- Y- Z axis format: 800- 300- 400 mm
Y- Z auxiliary axis format: 100-100 mm
Min- Max press diameter: 0.5- 25 mm
Mandrel Conicity: ISO 40
Table working surface: 1000x440 mm
Min- Max RPM: 25- 2500
Vertical Milling Machines
In vertical milling machines the controls are similar to those of universal models. The
vertical milling machines are particularly useful in tool and die work, where elevations,
depressions, slots etc. are called on the work piece. There are two vertical milling machines in
the machine shop of the factory.
20
HECKERT Vertical Milling Machines
Number of machines: 2
Power: 11kw / 15 HP
X- Y- Z axis format: 1120- 360- 400 mm
Z axis auxiliary axis format: 110 mm
Min – Max RPM: 28- 800
Table working surface: 1600x400 mm
CNC Machining
There is one CNC horizontal machine in machine shop of the factory for mass
production of the circuit breakers and disconnectors parts.
FINN Power CNC Horizontal Machine
Number of machines: 1
Model: X5
Power: 18.5 kW
Face milling: 275 RPM
End milling: 180 RPM
Drilling: 660 RPM
Tapping: 61 RPM
Table working size: 600x600 mm
Axis Stroke: X- 1250 mm, Y- 1000 mm
Drilling Machines
Some drilling machines are used for basic hole making operations in various types of
parts in TEMSAN. Drilling holes, increasing holes, and countersink operations are some of
machining operations that are made in these drills.
21
Radial Drills
Radial drills are convenient for heavy work pieces that can not be moved around easily
or, are too large for other kinds of drill presses. The drill spindle is fed up and down by hand
or power.
ALLZMETALL Radial Drills
Number of machines: 9
Power: 2.4 kW / 3.2 HP
Min- Max RPM: 56- 1250
Max drill diameter: 50 mm
Table working surface: 560x470 mm
Head turning angle: 360
SOLID Drilling Machines
Number of machines: 5
Model: B 35 VS
Power: 2.9 / 3.9 HP
Min- Max RPM: 70- 1200
Max Drilling diameter: 60 mm
Table working surface: 2100x400 mm
SOLID Drilling Machines
Number of machines: 4
Model: R 16 S
Power: 0.74 / 1HP
Min- Max RPM: 250- 4000
Max drilling diameter: 70 mm
Table working surface: 1400x400 mm
22
SOLID Drilling Machine
Number of machines: 8
Model: R 16
Power: 0.74 kW / 1HP
Min- Max RPM: 200- 2800
Max drilling diameter: 70 mm
Table working surface: 2100x400 mm
Presses
Eccentric and hydraulic presses are used for mainly in mechanical workshop of
TEMSAN. Presses with 80 tons capacity and hydraulic presses with 40 tons capacity can be
used for cold shaping processes.
DARLEY ARKANT Hydraulic Presses
Number of machines: 3
Max pressing force: 40 tons
Max length: 3100 mm
Max descent speed: 100 mm/min
Max ascent speed: 150 mm/min
Stroke: 100 mm/min
Power: 5.5 kW
DARLEY ARKANT Eccentric Presses
Number of machines: 3
Max pressing force: 80 tons
Stroke: 150 mm/min
Power: 5.5 kW
23
Welding
MIG / MAG Welders are used to permanently assembly the components of circuit
breakers together.
MESSER GREISHEM Gas Welding Machines
Number of machines: 7
Welding Voltage: 10- 24 V
Output current: 20 / 300 A
MESSER GREISHEM CNC Oxy Cutting Machine
Number of machines: 1
Max cutting dimensions: 3000x3100 mm
Min- Max cutting thickness: 3- 200 mm
Max cutting speed: 1000mm/min
Cutting point: 4
Other Machines in Machine Shop
TACHELLA Universal Grinding Machines
Number of machines: 2
Motor Power: 2.5 kW
Max grinding diameter: 250 mm
Working surface: 900x205 mm
Min- Max RPM: 2200- 3200
Table turning angle: 360
24
STEINEL Riveting Machine
Number of machines: 1
Max riveting diameter: 9 mm
Max pressure: 260 KP
Max stroke: 55mm/min
Min –Max motor RPM: 1400- 2800
Power: 2.2 kW
Guillotine Cutter
Cutting capacity: 14x1500mm
16x800 mm
SOLO Temper Furnace
Number of machines: 1
Connection Voltage: 3x 380 V
Max heating: 1050 C
25
PRODUCTION ANALYSIS OF SAMPLE WORK PIECES
Wicket Gate (Regulating Panel)
Material: GX4CrNi 13-4- Q1
Material Number: 1.4317
Drawing Number: D.22332.30.034
Operations Applied
Cast material comes to the machine shop.
The material is controlled.
Rough turning operations are applied at TEZSAN SN 50 lathes.
Ultrasonic controls are applied.
At this step, if a problem occurs in the casting part of material (holes, crack),
production is stopped and problem is solved by using stainless electrodes at
casting part
If there is no problem, manufacturing process continue with turning
operations.
The work piece is fixed to the chuck of TEZSAN SN 50 lathes again.
M20 X 42 hole is drilled
Using a mandrel, Ø100f7 x 140 and Ø110d9 x 240 holes are drilled and
tapped.
Ø120f7 x 100 and Ø190 x 10 holes are drilled.
Work piece is reversed and fixed to the chuck again.
Ø90f7 x 125 and Ø140 x 10 holes are drilled and tapped.
At FRITZ WERNER Horizontal milling machine, milling operations for the casting
part (wicket) is applied. (Wicket cutting).
Wicket part is rubbed.
The work piece is washed and cleaned all chips and dried with air.
26
Wicket gates are used for regulating water amount which is used for hydro electric
power plants. With the help of wicket gates, small or large amount of electric power is
produced which depends on public requirements.
Key Part of Connector
Material: S235J263
Drawing Number: D.42673.036
Operations Applied
The material is controlled.
Steel work piece is cut roughly with MEISSER GREISSEM CNC oxy cutting machine.
In milling and drilling department of machine shop, cleaning step is done.
Using an apparatus, the work piece is fixed at the HECKERT Vertical milling
machine.
Ø14 x 4 holes are drilled.
Ø7 x 3 holes with 5 mm deep are drilled.
60 degree incline is given two of outer surface.
The height of work piece is reduced from 40 mm to 34 mm.
The work piece is reversed.
41 mm width and 5 mm deep chamfer operation is done.
275 mm work piece width is provided.
At SOLID Radial drill, M16 x 4 gear operations are applied.
The work piece is washed and cleaned from all chips and dried with air.
This key part is used for the connection part of stators at Alpaslan Hydro Electric Power
Plant in Turkey.
27
Laminated Rim
Material: 42 CrMo 4
Drawing Number: D.42596.599.031
Operations Applied
Material comes to the machine shop with large dimensions.
Material is controlled
To achieve desirable dimensions, sawing operations are applied.
At TEZSAN SN 50 Universal lathe, turning operations are applied:
40 mm outer diameter is reduced to 38 mm.
Work piece is reversed in order to reduce outer diameter of other part to 38
mm (because of the long length of work piece)
M36 x 2 gear operations are applied to the two end of work piece.
Work piece is washed and cleaned from all chips and dried with air.
As a covering operation, material is covered with galvanize.
In order to prevent vibration of the work piece, resulted from long height,
special mandrels used on lathes.
In order to prevent thermal disadvantages, lubricating oil is used during the
turning operations.
Laminated rim is used for the connection of the stators at the side points at
Alpaslan Hydro Electric Power Plant in Turkey.
28
29
30