MIDDLE EAST TECHNICAL UNIVERSITY

DEPARTMENT OF MECHANICAL
ENGINEERING

ME 300
SUMMER PRACTICE
REPORT

Name:Mustafa zgr ALTINAY

Number:1199983
Year:2002

TABLE OF CONTENTS
DESCRIPTION OF OTOSAN..................................................................
HISTORY OF OTOSAN................1
INTRODUCTION...6
THE REPORT.7
Chip Removal Processes.7
Manufacturing with CNC Machines....8
Broaching ..............................................................................................
Milling ...................................................................................................
Turning and Boring ...............................................................................
Lathes ....................................................................................................
Grinding ................................................................................................
Honing ...................................................................................................
Drilling and Reaming ............................................................................
Gas Welding ..............................................................................................
Heat Treatment Processes..42
Carburizing .............................................................................................
Induction Hardening ...............................................................................
Quenching ...............................................................................................
Tempering ...............................................................................................
Annealing ................................................................................................
Nitriding ..................................................................................................
Production Analysis of The 5 Sample Products...45
Connecting Rod .....................................................................................
Cam shaft ...............................................................................................
Rear Axle ...............................................................................................
Fly-wheel ...............................................................................................
Pinion .....................................................................................................
CONCLUSION....50
APPENDIX 1...52
APPENDIX 2...
2

COMPANY NAME:

FORD OTOSAN
Company Location:
FORD OTOSAN is located in Inn,approximately 45 km far from Eskisehir.

Main Area Of Business:

Automotive Industry

A Brief History:
Ko became a Ford dealership in 1928.The FORD OTOSAN AUTOMOTIVE
COMPANY was founded in 1959 and it has started manufacturing in 1960.An agreement sign
with Ford in 1961 enabled OTOSAN to manufacture vehicles with import parts from the
US.The company has two plants;one in Istanbul, the other in Inn-Eskisehir. The Inn Plant
was founded in 1981 and began mass production 1982,and it was again OTOSAN that
produced Turkey's first diesel engines.It was constructed like an example of the Ford plants in
Valencia and Spain by using sandwich panels without windows that prevents heat loss.At the
beginning of the foundation the plant was a manufacture plant of internal combustion engines,
diesel and gasoline engines. But after Ford Motor Company bought a 30% share in Otosan,the
Cargo trucks manufacturing was started.
Otosan was started manufacturing of Ford trucks in 1960, Consul in 1961 and Taunus
17M SW in 1963. After this in 1966 the first Turkish automobile ANADOL was
manufactured. Today the products of the company are 2,5 lt. DI (Transit engines) engines and
complete Cargo trucks also PUMA engines,which are the new models.
The cast products are bought from Dktap Casting Company which is a member of Ko
Group. Some other casted and forged workpieces, piston,segments,valves and valve springs ,
injectors, distributors, alternators, exhaust and vacuum manifolds are obtained from the
subindustry of the company. Injection pumps, carburators and bearings are imported.
Ford Otosan is widely using high technology in manufacturing,assembly and supporting
areas.It is awarded 4 times in high technology by Eskisehir Chamber of Industry.
Ford Otosan applies all FORD Quality Systems parallel to FORD such as FORD Q1 and
ISO9001.
Brief history of FORD OTOSAN;
Feb 1978
Feasibility Studies Of Engine Plant.
Oct 1979
Credits and Encouragements.
th
14 Sept 1979
Ceromony of Engine Plant Foundation.
Sep 1981
Engine Plant Construction.
Jan 1983
Engine Production Exercises.
Feb 1983
Engine Serial Production.
April 1983
Truck Plant Ceromony.
April 1984
Construction of Truck Plant.
May 1984
Truck Production Exercises.
Sept 1984
Truck Serial Production.
3

Jan 1992
July 1992
May 1993
Sept 1993
Jan 1993
July 1993
Aug 1993
Jan 1995
Jan 1997
Sept 1997
Jan 1998
Sept 1998
Dec 1998
Dec 1999
Dec 2000

TCI Dover Engine Production.

Projects of DI and Differential Gear production.
Exercise of DI and Differential Gear production.
Serial Production of DI and Differential Gear.
FRP and Painthouse Construction.
Exercise of FRP-Painthouse.
Serial Production in FRP-Painthouse.
MT-75 Transmission Serial Production.
ZETEC CFI Engine Serial Production.
Transit Rear Axle Serial Production.
(Transferred from Istanbul)
98 MY Cargo launch.
Cargo Chassis Press Shop Serial Production.
(Transferred from Istanbul)
500K Dover Engine Serial Production.
Cargo XX27 Serial Production.
New Transit Engine /Transmission/Rear Axle Production

PLANT AREA
TOTAL AREA

1095000 m

Engine&Transmission Plant
Truck Assembly Plant
FRP&Painting Workshop
Press-Weld-Paint Shop
Heat Treatment Building
Facilities

27480 m
12400 m
6000 m
3400 m
2300 m
6700 m

TOTAL COVERED AREA

58280 m

QUALITY IMPROVEMENT HISTORY

FORD Supplier Quality Assurance
1984 First Appraisal
1985 System Survey Rating:143
1986 Supplier Q1 Award
FORD Quality Award
1999 Ford Worldwide "Customer-Driven Quality Award"Targeted for year
2000 again
ISO Certification
1997 ISO 9001 Certified by VCA
1998 ISO 14001 Certified by BVQI
Eskisehir Chamber of Industry Technology Prizes
1989 Electro-optical Control Appratus
1990 Camshaft Measurement Software
1995 Implementation of Advanced Technology on MT-75

1999 Technology Improvement Award on RF/Barcoding System

Quality Methods
1987 Statistical Process Control
1988 Failure Mode Effect Analysis
1989 Taguchi Experiments
1997 8D Applications
1997 AQP Applications
1998 PDI
1998 Nova-C
PRODUCTION VARIABILITY
Inn Plant has a huge product variability and about 200 different componenets are
manufactured.The main products are trucks,engines and transmissions.Spare parts are as
flywheels,camshaft,blocks,heads,rocker arms etc.Products for other Ko factories are as front
axle to Tofas.
PRODUCTION PROCESS
Marketing department gets orders from the dealers every month and distributes them
according to their priority.Planning department prepares monthly and daily production
programs according to the orders and gives workflow to the production lines.Planning
department is also responsible for storage,material handling and control.Purchasing
department is in contact with suppliers to purchase materials according to monthly production
programs.Materials are stored in general stores and only daily usage amounts are stored near
production lines.Production is done according to daily production programs in assembly and
semi-product lines.All the finished products are tested after production and sent to customer
park.After sales,Product Development department changes and solves the design problems
according to customer complaints and the Service department solves the service problems.
PARTS MANUFACTURED AT NN PLANT
Engine
Cap
Front axle
Hubs&Drums
Spindle arms
Clutch housing
Chassis side members
Chassis cross members
Cylinder block
Cylinder head
Crank shaft
Cam shaft
Connecting rod
Flywheel
Rocker arm
Oil pan
All gears
Cone gears
Bearing retainer

Driving flange
Differential housing
Ring and pinion gears
Differential case
6 cylinder Dover Tech. Generator Engines
6 cylinder Dover Tech. Marine Engines
4 cylinder 2,5DI Generator Engines
4 cylinder 2,5DI Marine Engines
CURRENT CAPACITY (UNIT/YEAR);
2,5 DI ENGINE............................45000(3 SHIFTS)
DOVER ENGINE.........................10000(3 SHIFTS)
MT75 TRANSMISSION..............40000(3 SHIFTS)
CARGO TRUCK..........................14000(2 SHIFTS)
PERSONAL DISTRIBUTION
Manager
10
Team Leader
36
Engineer
64
Technician
31
Staff
12
Total monthly salaried
153
Total hourly paid
794
TOTAL
936
ENGINEER DISTRIBUTION
Mechanical
37
Aircraft
14
Industrial
6
Electronic
2
Metallurgical
2
Physics
1
Chemical
1
Environmental
1
Engineers in OTOSAN are mainly graduated from Osmangazi,Metu and Itu,nearly
%85 of managers are engineer.
EDUCATIONAL STATUS
University
Technical-high school
Others

% 8,4
% 73,2
% 18,4

AVERAGE AGE
Salaried
Hourly paid
Total

36
30,1
30,7

Manufacturing Engineer is responsible for;

Establishing methods for producing new project parts,machine capacity studies,to

make or buy new machines,production areas machine layouts,fixture designs and productions,
preproduction of these new project parts according to quality and environmental requirements
and policies.
Coordinate advanced quality planning activities.
Support project,manufacturing and maintenance activities with toolshop
opportunities.
Production Planning Engineer is responsible for;
Ensuring that materials are delivered,handled and stored in accordance with relevant
ES procedures.
Preparing the needs according to the production program
-Installing the supplies on the production lines
-Designing suitable systems by being in supply management system
-Adapting the software in use to the system and making required changes
-Preparing reports about production and stocking and analyzing the results and
improving the work
-Determining the computer software and education needs of the plant
-Planning the activities of stock reducing
-Planning the material flow and reduce in stock costs
In OTOSAN
a)Conventional type machines are used in;
All types of cutting, shearing, turning, milling, grinding, drilling&boring operations.
b)CNC type machines are used in;
Milling, drilling, reaming, boring, facing, turning operations.
Number of machines used in each production area.
Area

Conventional type CNC

machines
Rear axle
7
6
Connecting rod
41
8
Block
55
16
Pipe flange
11
2
Pipe welding
10
1
Differential gears 11
5
Heat treatment
6
1
Flywheel
13
8

Area
Pinion spider
Head
Camshaft
Cap
Crankshaft
Hub
Rocker arm
Transmission

Conventional type CNC

machines
8
3
43
8
17
3
13
2
40
10
18
4
15
50
48

INTRODUCTION
Mechanical engineering is one of the most important work area in todays world. This
makes the education of mechanical engineering students fairly important. We are able to
notice the place of engineers in wide range of areas not only in the industry but also in the
social life.
As being mechanical engineer candidates, we should start getting experienced in the
professional life and this summer practice program is the first serious one. The ME 300
summer practice program is based on the production techniques that are used in the company
and it is required to make observations about the processes that are carried out.
The main aims of this summer practice program are;
- To improve the professional knowledge, ability and behaviours by practice.
- To provide the adaptations of the real professional life in real production conditions.
- To provide an opportunity to be introduced with the machines that are not available
in our university.
- To learn the sophisticated administration methods.
- To improve and reinforce the theoretical and practical knowledge on production
techniques that are acquired from the ME 200 and ME 202 courses and engineering drawing
that is get from the ME 113 and ME 114 courses.
Practise done in discipline and seriously prepared report including the examined things in the
factory is an important part in an education of an engineering student and it will also be useful
for the future. Moreover it is important to get used to the factory atmosphere as it is another
world with its own rules and relations among employees; especially among engineers and
worker.
The production techniques employed in this organization are; broaching, milling,
turning and boring, drilling and reaming, press works, abrasive machining processes such as;
grinding and honing, also heat treatment processes.
Manufacturing With CNC Machines:
In FORD OTOSANs mechanical workshops, CNC workbenches are widely used for
chip forming manufacturing applications.
CNC (Computer Numerical Control): CNC work machines are the ones that functions
and movements of which are controlled by computers. Having all the basic properties of NC
(Numerical Control) workbenches, CNC machines have a memory in addition. This memory
provides excessive flexibility and adaptability to CNC machines, making them the best choice
in many industrial fields as metal formation.
Manufacturing of a workpiece in a CNC machine involves two steps: Preparation of
the CNC, CNC functions:
Preparation: A manufacturing plan according to technical drawings and the
technological data about the workpiece is prepared. Then, using this plan, piece program is
coded using specific software codes. After that, the piece program is input to the CNC

machine using the machines keyboard or by a connection through the CNC machine and
another computer.
CNC functions: The Programmable Logic Control Unit (PLC) reads the data in the
CNC memory continuously. These data are then processed in the computer. The processed
data is then used to move the related tools on the machine. Finally, the motion of the tools and
the piece are controlled by the PLC to ensure the quality.
CNC machines have many advantages when compared with conventional machines.
They increase the production rate and highest rate of dimensional accuracy can be achieved
due to their high technology. The surface quality is also much better than traditional chip
forming machines. They are also capable to process complex shapes. All of the main metal
cutting processes like drilling, reaming, boring, tapping and milling, including every type of
them, can be done by these machines owing to their high capacity of magazines on which up
to 40 tools can be mounted. These machines are fully automatic and can be programmed
easily for a very large variety of different and complicated machining processes. Therefore the
necessity of high skilled labor is eliminated which is a very important fact for the production
cost.
The CNC machines have some disadvantages that must be considered too. Firstly,
their initial cost is quite high. Secondly, since they are very sensitive, they must be protected
from the environmental effects better than conventional machines. They also have a higher
possibility to break down, which increase the need for qualified maintenance and service
operators. Finally, they need skilled operators that will involve in the programming step.
In OTOSAN, there are two widely used CNC systems; Mazak and Mori Seiki
Properties of MORI SEIKI SH-500/50 model are as follows;
Table working surface
mm
Table loading capacity
kg
Max. Spindle speed
1/min
Tool changing time(tool-to-tool)
sec
X-axis travel(longitudinal movement of column) mm
Z-axis travel(cross movement of table)
mm
Y-axis travel(vertical movement of spindle head) mm

500*500
500
10000
2
630
850
600

Properties of some model of MORI SEIKI CNC MACHINES used in this company.
ITEM
Swing over bed
Swing over cross slide
Capacity Max turning diameter
Standart turning diameter
Max turning length
Travel
X-axis travel
Z-axis travel
Spindle Spindle speed range
Turret
Number of tool stations
Turret indexing time
Tailstock Tailstock travel

SL-150
mm
mm
mm
mm
mm
mm
mm
1/min
sec
mm

184

SL-150MC
620
455
430
170
500
230
520
50-5000
12
0,2
515

SL-150S

184
350

Feedrate
Tank
capacity
Power
sources
Machine
size

Feed per revolution

Coolant tank capacity
Electrical power supply
Machine height
Mass of machine

mm
L
kVA
mm
kg

0,001-480
160
18
4000

Item
X-axis travel(longitudinal movement of saddle) mm
Y-axis travel(cross movement of column)
mm
Travel
Z-axis travel(vertical movement of spindle head) mm
Table
Table loading capacity
kg
Spindle
Max spindle speed
1/min
Feed rate
Feed rate
mm/min
Tool storage capacity
Max tool diameter
mm
ATC
Max tool length
mm
Tool changing time (tool-to-tool)
sec
Tank capacity Coolant tank capacity
L
Power supply Electrical power supply
kVA
Machine size Machine height
mm
Mass of machine
kg

21
1790
4100
CV500A
510

10

4100
CV-500B
1020
510
510

350

700

8000
1-10000
25
100
250
2,2
200
22,5
2745
3900
4400

Properties of some model of MAZAK LATHES used in this company.

(QTN means; quick turn)
ITEM
QTN20
QTN30
Capacity
Max turning diameter
mm
300
310
Max turning length
mm
446
956
X-axis travel
mm
180
200
Travel
Z-axis travel
mm
510
1020
X-axis max cutting speed
m/min
5
5
Z-axis max cutting speed
m/min
5
5
Turret
Number of tools
8
8
Tool changing time
sec
0,35
0,60
Power source
Electrical power supply
kVA
23,4
37,6
Machine size
Machine height
mm
1855
1845
Mass of machine
kg
4250
5300
MAZAK CNC MACHINES

29

QTN40
400
1024
280
1052
5
5
12
1,00
44,8
1890
5700

MODEL

H 630

H 800

H1000

Face milling RPM

End milling RPM
Drilling RPM
Tapping RPM
Pallet table size
Axis stroke
Power

300
172
110
43
630*630 mm
X-1000 mm
y-800 mm
18.5 kw

275
180
660
61
800*800 mm
X-1250 mm
Y-1000 mm
18.5 kw

350
510
110
43
1000*1000 mm
X-1640 mm
Y-1220 mm
18.5 kw

MODEL

H 630 NX

H-500/50 N

Face milling RPM

End milling RPM
Drilling RPM
Tapping RPM
Pallet table size
Axis stroke

300
320
110
43
630*630 mm
X-1000 mm
Y-800 mm

Power

18.5 kw

338
239
159
99
500*500 mm
X-720 mm
Y-650 mm
Z-650 mm
11 kw

HITACHI SEIKI CNC MACHINE:

Model: HC 500
Power: 11 kW
X-axis travel: 710 mm
Y-axis travel: 630 mm
Z-axis travel: 560 mm
Spindle speed: 20-3600 rpm
Table size: 500x500 mm

Broaching:
The process of broaching is one of the most productive of the basic manufacturing
processes.. 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 . The profile of the
machined surface is the inverse of the profile of the broach. The cutting action is performed in
a fixed, and with one stroke of the broach the process is completed.Roughing, semifinishing
and finishing teeth, consequently the related processes are combined in a single tool. The last
teeth on the cutting tool conforming to the desired shape of the finished surface.
A broach is composed of a series of teeth, each tooth standing slightly higher than
last. This rise determines the depth of cut by each tooth, so that no feeding of the broaching
tool is required. As the result of these conditions, complex tool motions are not required and
the need for skilled labor is minimized.Also,the rate of production is high because the actual
cutting time is a matter of seconds and this process can be used for either internal or external
surface finishing.In spite of all advantages broaching has some disadvantages such as;cost of

11

tool is high for this reason short-run jobs are not advisable.Broaching has been adopted for
mass production work, like in this company.
Horizontal Broaching Machine:
Horizontal broaching machines are used to make possible longer strokes and the use of
longer broaches. The broach must have a diameter to length ratio large enough to make it selfsupporting without appreciable deflection. Therefore, they are mostly used for large holes.
Lapointe Horizontal Broaching Machine:
Model: R1S206X16X5
Power: 11.04 kW
Capacity: 50 tons
Max. stroke: 2 m

Milling:
.

Milling is a basic machining process by which a surface is generated progressively

by the removal of chips from a workpiece fed into a rotating cutter in a direction
perpendicular to axis of the cutter. Sometimes, the workpiece remains stationary, and the
cutter is fed to the work. The workpiece is clamped in a vise or fixture, which is located on
the worktable. As the workpiece is moved past or into the rotating cutter, it receives the
required shape, form or surface. Flat or curved surfaces, inside or outside, of almost all shapes
and sizes can be machined by milling.
In nearly all cases, a multiple-tooth cutter is used so that material removal rate is
high.The desired surface is obtained with a single pass of the cutter and the surface finish is
very good, milling is widely used for mass-production work. The surface to be generated can
be perpendicular or parallel to the axis of the cutter. As the material removal rates are very
high due to the number of cutting teeth, it is also a very rapid process, which makes it
preferrable among other possibilities in certain applications. It is sure that, more flat surfaces
are produced by milling than by any other machining process.
In milling, surfaces can be generated by two distinctly different methods. Up milling
is the traditional way to mill and is called conventional milling. The cutter rotates against the
direction of feed of the workpiece. In down milling, the 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, where the tooth first contacts the work and increases in
thickness, becoming a maximum where the tooth leaves the work. The cutter tends to push the
work along and lift it upward from the table. The action tends to eliminate any effect of
looseness in the feed screw and nut of the milling machine and results in a smooth cut.
However, the action also tends to loosen the work from the clamping device, therefore greater
clamping forces must be employed. In addition, the smoothness of the generated surface
depends greatly on the sharpness of the cutting edges. If milling conditions create a built up
edge, the built up edge will not affect the surface in up milling.
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 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.
12

Virtually all modern milling machines are capable of doing down milling. Because the
material yields in approximately a tangential direction at the end of the tooth engagement,
there are fewer tendencies for the machined surface to show tooth marks, and the process of
cutting is similar with less chatter. Another advantage of down milling is that the cutting force
tends to hold the work against the machine table, permitting lower clamping forces. However,
the fact that the cutter teeth strike against the surface of the work at the beginning of each chip
can be a disadvantage if the workpiece has a hard surface, as castings sometimes do. This may
cause teeth to dull rapidly. Metals that readily work-harden should be climb milled.
Cincinnati Horizontal Milling Machines:
MODEL
Power
Mors taper no
Rpm
Left/right motion of the table
Back/front motion of the table
Up/down motion of the table

2P
16.05 kw
50 MTS
20-1500
711.2 mm
254 mm
482.6 mm

3P
16.05 kw
50 LTS
18-1300
863.6 mm
304.8 mm
508 mm

4P
10 HP
50 LTS
18-450
1066.8 mm
355.6 mm
508 mm

Cincinnati Vertical Milling Machines:

MODEL
Power
Mors taper no
Rpm
Left/right motion of the table
Back/front motion of the table
Up/down motion of the table

2V
3.68 kw
50 MTS
20-1500
711.2 mm
304.8 mm
330.2 mm

3V
3.86 kw
50 MTS
18-1300
803.6 mm
406.4 mm
406.4 mm

Turning And Boring:

Turning provides a widely used means for machining external cylindrical and conical
surfaces. In turning, the workpiece rotates and a longitudinally fed single point cutter does the
cutting.External cylindrical, conical and irregular surfaces of limited length can also be turned
by using a tool having a specific shape and feeding it inward against the work. The shape of
the resulting surface is determined by the shape and size of the cutting tool. Machine tools
used for this process are called lathes.In order to have good surface quality, roughing cuts are
followed by usually finishing cuts. If the tool is fed at an angle to the axis of rotation, an
external conical surface results. This is called taper turning. If the tool is fed at 90, the
operation is called facing. Facing produces a flat surface. External cylindrical, conical and
irregular surfaces of limited lengths 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. Such machining is called form turning. If feeding of the tool
continues to the axis of the workpiece, it will be cut in two. This process is called cutoff, and a
simple, thin tool is used. Knurling produces a regularly shaped, roughened surface on a
workpiece. In most cases, knurling is a chipless cold forming process.
13

Boring is the process of enlarging an existing hole,which may have been made by
drilling or be the result of a core in casting.Principally it is an operation of truing a hole that
has been drilled previously with a single point lathe type tool.It is performed by rotating the
workpiece and feeding the tool through the workpiece. An equally important 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 drill having drifted off the centerline.
Holes may be bored straight, tapered or to irregular contours. Precision in boring is essentially
the same as turning.
When boring is done on a lathe, the work usually is held on a chuck or on a
faceplate.
Several machine tools have been primarily designed for boring, especially where
large workpieces are involved or for large volume boring of smaller parts.Since boring
frequently follows drilling, many boring machines also can do drilling, permitting both
operations to be done with a single setup of the work.
Lathes:
Lathes are capable of performing a variety of processes such as;turning,boring,
facing,cut off or parting,drilling,reaming,knurling and thread cutting.Parts to be machined can
be held between centers,attached to a faceplate,supported in a jaw chuck, or held in a draw-in
chuck or collet.
The essential components of a lathe are;the bed, headstock assembly, carriage
assembly, tailstock assembly, quickchange gearbox, leadscrew and feed rod.
Modern lathes have quick-change gearboxes driven from the spindle by means of a
suitable gearing and connected to the feed rod and lead screw. Therefore, through the quickchange gearbox, the associated gearing, the lead screw, feed rod, the carriage is connected to
the spindle, and the cutting tool can be made to move a specific distance, either longitudinally
or transversely, for each revolution of the spindle.
In OTOSAN, many of the lathes are CNC machines. They are generally of medium
size (swing and distance between centers).All lathes are turret lathes, and they are mainly
automatic turret lathes. There are also a moderate amount of Swiss-Type screw machines.
There are few boring machines in OTOSAN, since the wide usage of multi-purpose drills
removes the need for them.
Vertical Lathes:
These lathes have a rotating table. Turning, facing and drilling can also be done on
these machines. Generally used for larger workpieces.
Hessap CNC Vertical Lathe:
Model: DV 62-2 (DV-60)
Power: 130.3 kW
Swing diameter:700 mm
Turning diameter: 650 mm
X-stroke: 600 mm
Z-stoke: 600 mm
Max. RPM: 1100
Emag CNC Vertical Lathe:
Model: VSC 01/500
Power: 44 kW
Max. turning diameter: 400 mm

14

Max. turning length: 250 mm

X-axis stroke: 880 mm
Z-axis stroke: 400 mm
Max. spindle speed: 3400 rpm
Horizontal Lathes:
These lathes are used especially for machining of large workpieces like the rear axle
of the tractor. Maximum 12 tools can be mounted to the turret. The workpiece is supported
between the chuck and the center.
Matrix Churchill CNC Horizontal Lathe:
Model: CTC 3
Power: 28.6 kW
Max. turning diameter: 300 mm
Z-axis stroke: 1000 mm
X-axis stroke: 200 mm
Max. turret tool swing radius: 200 mm
Speed range: 12-4000 rpm
Matrix Churchill CNC Horizontal Lathe:
Model: CTC 4 HS X 0.5
Power: 28.6 kW
Max. turning diameter: 300 mm
Z-axis stroke: 520 mm
X-axis stroke: 275 mm
Speed range: 12-4000 rpm
Mazak CNC Horizontal Lathe:
Model:QT-15 N-U
Power: 14.5 kW
Max. turning diameter: 300 mm
Max. turning length:500 mm
Max. swing diameter: 440 mm

Grinding:
Grinding is a material removal process which produces chips that are very small in
size. With this property, it is suitable for removing small amounts of material in order to
provide dimensional accuracy. There are various types of grinding processes, however the
main idea is to rub a wheel consisting of abrasive particles, which is called grinding wheel, on
the surface whose dimensions are to be improved. The operation of grinding wheels is greatly
affected by the bonding material and the spatial arrangement of the abrasive particles, known
as the structure. A proper selection of grinding wheel should be made in order to avoid a
failure due to material properties In almost all cases, suitable lubricants are used in order to
cool the surfaces in contact and also to remove the chips and abrasives from the working
area.The grinding process has some advantages such as;
Because of the many small cutting edges of the wheel, it produces finishes that
are extremely smooth and satisfactory at contact and bearing surfaces.
Grinding can finish work to accurate dimensions in a short time.

15

In grinding, the feeds and depths of cut in is very small, thus the chips are small.
Most grinding wheels are identified by a standard marking system. If optimum results are to
be obtained, it is very important that the proper grinding wheel be selected for a given job.
Several factors must be considered. Probably the first is the shape and size of the wheel.
Obviously, the shape must permit proper contact between the wheel and the entire surface that
must be ground. Straight grinding wheels can be obtained with a variety of standard faces.
Grinding wheels lose their geometry during usage. Truing restores the original shape. A
single-point dressing tool made of diamond can be used to true the wheel by fracturing
abrasive grains to expose new grains and new cutting edges on worn grains.
Tacchella CNC Cylindrical Grinding Machine:
Model: Crossflex
Power: 22 kW
Max. grinding diameter: 300 mm
Max. traverse speed: 10000 mm/min
Height of centers: 205 mm

Oerlikon Mattison Surface Grinder:

Model: B 63227
Power: 83.48 kW
RPM: 750
Outer table size: 114 mm
Inner table size:104 mm

Honing:
Honing is a low velocity abrading process.Since material removal is accomplished at
lower cutting speed than in grinding, heat and pressure are minimized, resulting in excellent
size.Honing uses fine abrasive stones to remove very small amounts of metal. Besides sizing
operations, is largely used in order to get rid of the scratches that are produced during
grinding. It is especially important for inner surfaces of cylindrical surfaces.
Virtually all honing is done with stones made by bonding together various fine
artificial abrasives. Honing stones are different from grinding wheels because of the
additional materials such as sulfur, resin and wax; often are added to the bonding agent to
modify the cutting action.All honing gives a smooth finish with a characteristic crosshatch
appearance.The depth of these hone marks can be controlled by variations in pressure, speed
and type of abrasive used.
Honing usually is done with special equipment. Either flat or round surfaces may be
honed, but by far the majority of honing is done on internal, cylinder surfaces, such as
automobile cylinder walls. The honing stones are usually held in a honing head, with the
stones being held against the work with controlled, light pressure. The honing head is not
guided externally but, instead, floats in the hole, being guided by the work surface.

16

The stones are given a complex motion so as to prevent a single grit from repeating
its path over the work surface. Single and multiple spindle honing machines are available in
both horizontal and vertical types.
Jones & Shipman Honing Machine:
Model: VHM 18
Power: 4 kW
Stroke: 24.5 mm to 457.2 mm
Diameter range: up to 152.4 mm
Capacity: 150 litres
Speed: rotational 59 to 540 rpm

Drilling And Reaming:

In manufacturing, it is probable that more internal cylindrical surfaces -holes- are
produced than any other shape, and a large proportion of these are made by drilling. Drilling
is a widely used manufacturing process for hole making.Although it seems to be a relatively
simple process, substantial difficulties are encountered.There is a friction between the body
and the wall of the workpiece, resulting in heat addition due to chip formation. As a result of
these conditions, substantial difficulty can be experienced due to poor heat removal.Most
drilling is done with a tool having two cutting edges.
Multiple Spindle Drilling Machines:
These machines are used if a number of parallel holes must be drilled in a part. There
are many spindles driven by a single power head and fed simultaneously into the work.
Morando Multiple Spindle Drilling Machine:
Model: FM-24, FM-16
Power: 20.15 kW, 26.92 kW
Drill unit stroke length: 500 mm
Max. drilling diameter: 40 mm
Max. simultaneous drilling diameter: 22 mm
Drilling area size: 700x500 mm
Radial Drill:
Radial drills are convenient for heavy workpieces that cannot be moved around
easily or are too large for other kinds of drill presses.
Sass Radial Drill:
Model: TL 1600, TL 1300
Power: 5.65 kW
Max. drilling diameter(casting): 70 mm
Max. drilling diameter(steel): 50 mm
Stroke: 400 mm
Spindle motors taper no: 5
Feed: 0.09-1.5 mm/giro
Column Drill:A column on a base carries a table for the workpiece and a spindle
head. The table is raised or lowered manually by an elevating screw and can be clamped to
the column for rigidity. The spindle that drives the cutting tool revolves in the nonrevolving
quill that is fed up or down.

17

Rino Beradi Column Drill:

Model: WS 700-75
Power: 15.18 kW
Speed: 90-1100 RPM
Feed speed: 100-515 mm/min
Approach and rapid return speed: 600mm/min

Reaming is the removal of a small amount of material from the surface of a hole for
the two purposes
to bring holes to a more exact size,
to improve the finish of an existing hole.
Multi-edged cutting tools are used, and no special machines are built especially for
reaming, since 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.

Gas Welding :
Gas welding is a nonpressure process using heat from a gas flame. The flame is
applied directly to the metal edges to be joined and simultaneously to a filler metal in wire or
rod form, called the welding rod, which is melted to the joint. Gas welding has the advantage
of involving equipment that is portable and does not require an electric power source. The
surfaces to be welded and the welding rod are coated with flux, a fusible material that shields
the material from air, which would result in a defective weld.
Casting:
There were no casting processes made in the plant. All the cast materials are brought
by sub-industrial companies.

HEAT TREATMENT PROCESSES

CARBURIZING:
The function of a carburizing medium is to supply an adequate quantity of carbon for
absorbtion and diffusion into the steel.In current commercial practice, two main sources of
carbon are gases and easily vaporized hyrocarbons.
Gaseous sources of carbon:Gases most commonly used are natural gas and certain
propanes.Natural gas and propane are the preferred sources when available with high purities.
For uniform carburizing,circulation of furnace gases is necessary.In installations it is
essential that furnace have a high volume fan for forced circulation of the gases to all parts of
the work load.

18

This process, in brief, is heating iron or steel to a red heat in contact with some
carbonaceous material. Iron, at temperatures, close to and above its critical temperature has an
affinity for carbon. The carbon enters the metal to form a solid solution with iron and converts
the outer surface into a high carbon steel. By proper heat treatment such steel will have an
extremely hard surface on the outside and a soft ductile center.
This process is merely one of changing the carbon content of the surface steel which
makes it possible to obtain different physical properties in a given piece of steel.
Effect of temperature; The max. rate at which carbon can be added to steel is limited
by the rate of diffusion of carbon in austenite. For consistent results in carburizing,it is
important that temperature be uniform.Uniformity in various locations throughout the work
load depends on furnace design,load density,recirculation and heating rate.

INDUCTION HARDENING:
In the induction process, the local areas on the surface of the steels that have the
property of hardenability(those consist of more than % 0.35 C), are hardened up to a certain
depth. Induction means hardening the steel by the energy that appears due to the friction force
that comes out by the movement of electrons of the steel which is kept in a magnetic field in
the surface hardening by induction machines. The steel is first austenitized by this energy and
then hardened by watering.
Heat for induction hardening a steel or cast iron part may be generated within the
part by electromagnetic induction.Any electrical conductor can be heated by electromagnetic
induction.As alternating current from the converter flows the inductor, or work coil, a highly
concentrated,rapidly alternating magnetic field is established within the coil.The strength of
this field depends primarily on the magnitude of the current flowing in the coil.The magnetic
fiels thus established induces an electric potential in the part to be heated, and since the part
represents a closed circuit, the induced voltage causes the flow of the current.The resistance
of the part to the flow of the induced current causes heating by IR. This means of heating has
been employed in surface hardening.The principal metallurgical advantages that may be
obtained by surface hardening with induction include increased wear resistance and improved
fatigue strength. This process here described is commonly known as the Tocco process, and it
was developed for the purpose of surface-hardening crankshaft bearings and other similar
wearing surfaces. It differs from ordinary case-hardening practice in that the analysis of the
surface steel is not changed, the hardening being accomplished by an extremely rapid heating
and quenching of the wearing surface which has no effect on the interior core metal.
Another important advantage of this method of is; its rapidity of action, since it
requires only 5 seconds to heat the steel to a depth of 3,1mm. Obviously, this procedure
eliminates warping to a great extend and consequently necessitates only a small allowance for
grinding to the finished size. Medium-carbon steel has proved very satisfactory for parts
treated in this manner, and the nature of the process has practically eliminated the necessity of
using costly alloy steels.

QUENCHING:
Carbon is the main element that gives the property of hardenability to steels. Steels
must have at least % 0.35 carbon in order to have the property of hardenability. Quenching is
the process of forming martensite structure by cooling those steels with a proper speed.

19

Martensite structure has a high level of strength but it is very brittle. In order to be able to
machine the pieces, they must first be tempered.

TEMPERING:
The workpieces that have been hardened by rapid quenching is brittle and not
suitable for most cases. In this process, steels are heated up to the proper temperature in order
to achieve the aimed strength and reduce the permanent stresses.By tempering the hardness
and brittleness is reduced to desired values.As these properties are reduced, there is also a
decrease in tensile strength and an increase in the ductility and toughness of the workpiece.
The operation consist of the re-heating of hardened workpiece to some temperature below the
critical range, followed by any rate of cooling. Although this process softens workpiece, it
differs considerably from annealing. In that the process lends itself to close control of the
physical properties and in most cases does not soften the workpiece to the extent that
annealing would.
In the process of tempering some consideration should be given to time as well as to
temperature. Although most of the softening action occurs in the first few minutes after the
temperature is reached, there is some additional reduction in hardness if the temperature is
maintained for a prolonged time. Usual practice is to heat the steel to the desired temperature
and hold it there only long enough to have it uniformly heated.

ANNEALING:
The primary purpose of annealing is to soften hard workpieces so that it may be
machined or cold-worked. This is accomplished by heating the work to a temperature slightly
above the critical temperature, holding it there until the temperature of the workpiece is
uniform throughout and cooling at a slow rate. This is the full-annealing because it wipes out
all trace of previous structure and refines the crystalline structure in addition to softening the
metal and removes gases trapped in the metal during the initial casting.
When hardened steel is reheated to above the critical range, the constituents are
changed back into austenite and slow cooling then provides ample time for complete
transformation of the austenite into the softer constituents. For the hypoeutectoid steels these
constituents are pearlite and ferrite. It may noted by referring the equilibrium diagram that
the annealing temperature for hypoeutectoid steels is lower. All martensite is changed into
pearlite by heating above the lower critical range and slowly cooling. Any free cementite in
the steel is unaffected by the treatment.
The temperature to which a given steel is heated in this process depends on its
composition and for carbon steel it can be obtained readily form the partial iron-iron-carbide
equilibrium diagram. The heating rate should be consistent with the size and uniformity of
sections so that the entire part is brought up to temperature as uniformly as possible.
When the annealing temperature has been reached, the steel should be held there
until conditions are uniform throughout. This usually takes about 30 minutes for each
centimeter of the largest section. For maximum softness and ductility, the cooling rate should
be very slow, such as allowing the patterns to cool down with in the furnace. The higher the
carbon content, the slower must be this rate. Low carbon steels are cooled more rapidly.

20

NITRIDING:
Nitriding is somewhat similar to ordinary case hardening, but it uses a different
material and treatment to create the hard surface constituents. This is the process of diffusing
nitrogen rather than carbon to the steel. There must be enough space in the molecular
structure of steel for the diffusion of carbon in the case hardening process, but nitrogen atom
does not need any space to diffuse and forms Fe-N layer. As a result a hard layer is formed.
This is not a covering process and applied to increase the fatigue strength of steels which
results an 15 times increase in the life of the piece. This process also increases the resistance
of corrosion and help lubrication by keep the help of the pores that keeps the lubricants at the
surface.
In this process the metal is heated to temperature of around 950F and held there for a
period of time in contact with ammonia gas. Nitrogen form the gas is introduced into the steel,
forming very hard nitrides which are finely dispersed through the surface metal.
It has been found that nitrogen has greater hardening ability with certain elements
than with others ; hence , special nitriding alloy steels have been developed. Aluminum in
percentages of 1 to 1 has proved to be especially suitable in steel, as it combines with the
gas to form a very stable and hard constituent. The temperature of heating ranges from 850 to
1200F , although 960 to 975F is the temperature range generally used .
The nitriding process develops extreme hardness in the surface of steel. This hardness
ranges from 900 to 1100 Brinell, which is considerably higher than that obtained by ordinary
case hardening. Nitriding steels, by virtue of their alloying content, are stronger than ordinary
steels and respond readily to heat treatment. It is recommended that these steels be machined
and heat-treated before nitriding, as there is no scale or further work necessary after this
process. Fortunately, the structure and properties are not affected appreciably by the nitriding
treatment; and , since no quenching is necessary, there is little tendency to warp, develop
cracks, or change condition in any way. The surface effectively resists corrosive action of
water, salt water spray, alkalies, crude oil, and natural gas.
This process is used on many automotive, airplane and Diesel engine wearing parts, as
well as on numerous miscellaneous parts, such as pump shafts, gages, drawing dies, gears,
clutches, and mandrels. Its use is limited by the expense necessary for the treatment and the
comparatively thin case obtained.
Different than the operations described above there is also Phosphate Bathing in the
heat treatments plant. Some workpieces like mirror and pinion gears are in danger of
corrosion. Because of this they must be protected against corrosion by phosphate bathing. A
corrosion preventing film is formed on the surface of the workpiece by this mean. Not only
the differential gears are bathed but also according to the customer desires other parts are
phosphate bathed.
In the plant a sanding machine is also found. Toolmarks are found on the workpieces
sent from the motor plant. The finished surfaces must be clean and smooth, especially on
gears it is important because of the high friction forces created during the work. This
toolmarks creates sound on the gears and increase the friction and chip removal from the
contact surfaces. To overcome this problem a sand cabinet is set. The workpieces that are to
be sand bathed are located in the cabinet. The sand is sprayed on the workpieces and a very
small amount of metal is removed from the surfaces. The toolmarks are totally disappeared.

21

The machined workpieces are then loaded into the containers and carried to the
related workstations by the forklifts. The plant works non-stop and the continuity is obtained
with there working watches. Energy for the furnaces are obtained from an energy production
unit located next to this plant. LPG is used in burning of the furnaces.

PRODUCTION ANALYSIS OF THE 5 SAMPLE PRODUCTS

CONNECTING ROD PRODUCTION LINE
The connecting rod is a member of the machine that transfers the motion of the
pistons to the cranck shaft.The linear motion the pistons are given to the eccentric bearings,
arm bearings of the crankshaft and it is changed into rotational motion.Connecting rod has
two holes through which the piston pin is passed (small end) and the second hole is used to
fasten the rod to the arm bearings of the crank shaft.In this production line the connecting rod
of the Transit vans (LCX AND LCY MODELS) cargo trucks are manufactured.
Material of the connecting rod used in this production is; micro alloyed medium
carbon forged steel.
OPERATION 10&20;
MATISON ROTARY GRINDING MACHINE is used in this operation.
Operation Definition: (rough) Grinding of the 1st and 2nd sidefaces of the cap
Grinding of the 1st and 2nd sidefaces of the rod
Surface grinding is used primarily to grind flat surfaces. The Matison Rotary
Grinding Machine is a vertical spindle rotary table surface grinding type. This type of
machines have two or more grinding wheels and this provides rough and finish grinding in
one rotation of the table. This machine has 5 grinding wheels but only three of them are
used.Two of these three wheels are same which are used to grind workpiece roughly and
workpiece is initially ground by these two grinding wheels.In this operation special fixtures
which are fastened on rotary table are used to hold workpiece. Cap and rod are held by
different fixtures. Also in this operation mixture of multan and water is used as cutting fluid to
assure that chips are washed away and not trapped between the wheel and the workpiece.The
capacity of the machine used in this process is 30 pieces and workpieces are fastened to the
fixture by operator.
The suboperations in this operation are as follows; initially, cap is fastened to the
fixture by operator.Little amount of chip is removed by the first two grinding wheels but
surface is not good enough so one grinding operation is needed to obtain better surface and
this is accomplished by the third grinding wheel which is more precise than the other two
wheels.After table completes one rotation ,the operator turnovers the workpiece.Same
operations are applied to the the other face of the workpiece and operation is completed.Then
workpiece is cleaned with airgun.Same steps are applied for both rod and cap, only fixtures
used to fasten the cap and rod are different.

22

Surface finish of the workpiece is not good enough so some other grinding
operations must be applied in the following operations which is operation 110.After this
operation, cap is sent to broaching machine but some other operations are applied to the rod
before broachig.
OPERATION 25;
EXCELLO BORING MACHINE is used in this operation.
This operation is only for rod.
Operation Definition: Drilling of small end
Core drilling of this hole
Semi finish boring and chamfering
Finish boring
All these suboperations are done by this machine.
The reason for boring after drilling operations is; nonhomogeneties in workpiece and
imperfect geometries may also cause the hole to be oversize or offline.If accuracy in these
respects is desired, it is necessary to follow drilling by boring.
The rod is mounted to the special fixtures and all these suboperations are performed
in one rotation of the table.The diameter of the small end that we want to obtain is 32 mm.All
these subprocesses are performed to obtain this diameter value.Initially,it is drilled with twist
drill which is 23.5 mm in diamater then this hole is core drilled with 30,5 mm diameter core
drill.Afterwards this hole is semifinish bored and chamfered with another cutting tool which
is different from the previous one.Finally, the hole is finish bored with the insert(cutting tool)
which is used in semi finish boring and 32 mm diameter is obtained.
OPERATION 26;
Operation Definition: Chamfering with hand operation
This operation is only for rod.One side of the small end hole is chamfered in the
previous operation, in this operation the other side of the small end hole is chamfered.

OPERATION 30;
MAZAK H400N CNC MILLING MACHINE is used in this operation:
Operation Definition: Forming of bolt seat face by milling
The type of the machine used in this process is horizontal milling machine.
This operation is only for rod.In this operation 4 workpieces are mounted to the
special fixtures and milled simultaneously.During this process workpieces remain stationary
and the cutter is fed to the work.Desired surface is obtained in two pass of the cutter.This
operation is face milling operation in which the generated surface is at right angles to the
cutter axis.An inserted tooth type milling cutter is used and cutter body is made of steel with 6
teeth.Bor oil and water mixture is used as cutting fluid.

23

In this operation, 4 workpieces are fastened to the fixtures by operator.The

workpieces are rough milled in first pass of the cutters and finish milled in the second pass of
the cutters.Then same operation is applied to the other side(left side wrt operator).

OPERATION 35;
LAPOINTE CONTINUOS SURFACE BROACHING MACHINE is used in this
operation.
Operation Definition: Broaching of joint faces, side faces and half bore of cap and
rod
Broaching is capable of producing precision machined surfaces and usually
broaching produces better accuracy and finish than that can be obtained by milling and
reaming.In this type of machine the broaches (which are longer) are stationary and the work is
pulled past the cutters by means of an endless coveyor.Workpieces are held by special fixtures
attached to the conveyor chain so that workpieces are placed at one end of the machine and
removed automatically at the other end.Radius broach,forehead broach and sideface broach
are available on this machine.These broaches are composed of two parts.First part is used for
rough and second part is used for finish broaching.Mixture of bor oil and watre is used as
cutting fluid.
Workpieces are clamped to the fixtures by the operator.Inside the machine;
initially,workpiece is broached roughly then finish broached at the other part of the machine.

OPERATION 40;
KROMAS DEBURRING MACHINE is used in this operation.
Operation Definition: Deburring of broached surfaces
The workpiece is put into very large container of the machine which is full of with
deburring stones.Then machine is worked whose working principle is; shaking of stones.
Deburring stones (F101SC 25*15) and very little amount of deburring fluid (PB40) is
used.This operation takes nearly 100 min.

OPERATION 42,43;
CNC VERTICAL HITACHI VK45 MACHINE is used in this operation.
Operation Definition: Drilling and chamfering of bolt hole (for both cap and rod)
Forming of nut seat face by milling operation (for cap)
This machine is capable of drilling and milling operations.

24

Initially, two rods and two caps are fastened to the fixture and machine takes them
in.The subprocesses in this operation are as follows;
Bolt seat face of the rod is drilled to depth of 14 mm whose complete depth is 30 mm and
chamfered by special combination drill which is 10,7 mm in diameter.
Nut seat face of the cap is (face) milled with 4 teeth milling cutter.
Nut seat face is drilled to depth of 22mm and chamfered by special drill which is 10,7mm
in diameter.Then the hole is completely drilled with 10,24mm diameter drill.
First part of the operation is completed and workpieces are turned over for drilling of
their joint faces.

For the rod ;the rest of the hole which is not drilled is drilled completely drilled with
10,17mm diameter drill
For both rod and cap; joint faces of these holes are chamfered with 20mm diameter drill
and operation is completed.
Then gauge of the bore diameter is checked whether it is in limit range or not.
Cutting speed,feed rate and rotational speed of the machine in this subprocesses are
as follows;
FOR ROD;
Rotational speed (rpm) Cutting speed(m/min)
Drilling and chamfering 1100
40
of bolt seat face
Complete(finish)
1100
35
drilling
Chamfering of joint 1300
80
faces these holes

Feed rate
100
200
260

FOR CAP;
Rotational speed
Cutting speed Feed rate
(rpm)
(m/min)
Milling of nut seat face
2500
200
600
Drilling of hole to nut seat face
1100
40
320
Complete (finish) drilling of this hole
1100
35
200
Chamfering of joint faces these holes
1300
80
260

OPERATION 50;
OTOSAN NOTCHING MACHINE is used in this operation.
Operation Definition: Milling of bearing lock notches (for both cap and rod).

OPERATION 60;

25

MATTISON ROTARY GRINDING MACHINE is used in this operation.

Operation Definition: Grinding of joint faces of cap.
Grinding of joint faces of rod.
This operation is very similar to operation10 but there are some differences.In this
operation, there are two grinding wheels, which are same,and fixtures which stand on rotary
table are different from the ones used in operation10,also in this process workpieces are
fastened vertically.Mixture of multan and water is used as cutting fluid.
In this operation,workpiece is mounted to the fixtures by operator.Some amount of
chip is removed by 1st grinding wheel but surface is not good enough so very little amount of
chip is removed by the 2nd grinding wheel and desired dimensions are obtained with good
surface finish.
OPERATION 65;
(HAND OPERATION)
Operation Definition:
Deburr which is found in two holes of the rod is cleaned with small brush.
Deburr which is found in two holes of the cap is cleaned with use of air gun.
Deburr which formed after grinding joint faces are also cleaned.
After these processes,two bolts are partially passed through these holes.
OPERATION 70;
H.SHAND PRESS is used in this operation.
Operation Definition: Assembling of (2)bolts to connecting rod.
Bolts are completely passed through hole with use of the press.As a result of
this,some portion of the thread of the bolt is filled with chip and is washed away with air.
Then,cap is assembled to rod and slove nuts are assembled to bolts.
After this operation,these two parts become a single part which is called connecting
rod.
OPERATION 80;
ATLAS COPCO NUT SETTING MACHINE is used in this operation.
Operation Definition: Torqueing of nuts.
Connecting rod is fastened to special fixture,these two nuts are torqued by machine
and parts are completely assembled(joint).
OPERATION 90;
OTOSAN PRESS is used in this operation.

26

Operation Definition: Bushing of small end.(there are oil channels in bush)

OPERATION 100;
DRILLING MACHINE is used in this operation.
Operation Definition: Oil hole which is 9mm in diameter is drilled partway to small
end.
OPERATION 110;
MATTISON ROTARY GRINDING MACHINE is used in this operation.
Operation Definition: Finish grinding of side faces.
This operation is very similar to operation 10.The only difference is;the fixtures used
in this operation is different from the fixtures used in operation 10.Workpiece is fastened to
the fixture by operator and ground by these 3 grinding wheels respectively.
The amount of chip removal for each grinding wheel is as follows;
1st grinding wheel
2nd grinding wheel
3rd grinding wheel

1st sideface (mm) 2nd sideface(mm)

0,145
0,19
0,14
0,14
0,08
0,08

OPERATION 120;
SCHENK BALANCING MACHINE is used in this operation.
Operation Definition: Milling of large &small ends and weight correction.
The workpiece is fastened to the fixture by operator.First,large end is milled then
fixture rotates 180 about its own vertical axis afterwards,small end is milled.Then,weight of
the small and large end is checked whether it is in tolerances range or not.The values are as
follows;
Small end mass (gr) Large end mass (gr)
556,40610
806,46910

Total mass (gr)

1362,87520

As a result of this operation,length of all workpieces become same value.

OPERATION 130;
BERARDI K355 MACHINE is used in this operation.
Operation Definition: Rough&semifinish boring and chamfering of large end.
Finish boring of small end.
27

In this operation,workpiece is stationary and feed motion is performed by cutting tool

which is held by holding device.Workpiece is fastened to fixture by operator.Initially
workpiece is rough bored ( 63mm ) and chamfered at both sides.Then fixture rotates 180
about its own vertical axis.In the 2nd step large end is semifinish bored ( 63,463mm) and
small end is finish bored (as a brief;semifinish boring of large end and finish boring of small
end).Semifinish boring of large end and finsh boring of small end is done by different cutting
tools and these cutting tools are rotated by different spindles.As a result of this operation,the
diameter of large end is nearly 63,460mm.Mixture of bor oil and water is used as cutting fluid
in this operation.Finally,oil hole is deburred.
OPERATION 140;
JONES&SHIPMAN HONING MACHINE is used in this operation.
Operation Definition:Honing of large end.
Honing is used to remove very small amount of metal which uses fine abrasive
stones.Cutting speed is much lower than that of grinding.Honing is used to size and finish
bored holes(in the previous operation),remove common errors by boring.The stones are given
a complex motion (rotation is combined with an oscillatory axial motion).Coolants are
essential to the operation of this process to flush away small chips and to keep temperatures
uiform.In this operation, honilo 480 is used as coolant.
In this operation,workpiece is stationary(it is fastened to fixture),feed motion is done
by the honing stones.Then,gauge of diameter of the large end is chacked and at the end od this
operation diameter becomes 63,5130,1.
OPERATION 150;
GNPAR WASHING MACHINE is used in this operation.
Operation Definition: Workpieces are washed with the mixture of water and multan
P3T5175 (5%) fluid whose temperature is nearly 70C.Then,it is dried with air.Operation
takes nearly 3,45 min.
OPERATION 160;
ETAMIC GAUGE CONTROL DEVICE is used in this operation.(HAND
OPERATION)
Operation Definition: workpiece is checked whether its parallel twist is in tolerances
range or not.If necessary it must be straightened.
OPERATION 170;
(HAND OPERATION),(VISUAL INSPECT)
Operation Definition: Final inspection of workpiece.

28

Surfaces which were ground are checked whether there is damage or not.Also,quality
of the honing surface is checked whether there is any error marks left or not.If surface quality
are not good enough,these are rejected.
OPERATION 180;
(HAND OPERATION)
Operation Definition: Nut assembly.
Deburring of notch and oil hole with hand operation
Two nuts,which are assembled in operation 80, are removed from connecting rod
assembly and only one aliminium nut is assembled with the use of ATLAS COPCO
TORQUEING MACHINE. If there is no problem with workpiece then "OK" sign is marked on
workpiece.
OPERATION 190;
Operation Definition: Stock cap-rod assemblies.

2,5 DI CAMSHAFT PRODUCTION LINE

Camshaft; a shaft in the engine which has a series of cams for operating the valve
mechanisms.It is driven by gears or by sprockets and a toothed belt or chain from the
crankshaft.When the camshaft is driven by a timing chain,the crankshaft and the camshaft
rotate in the same direction.With gears,the camshaft rotates in the opposite direction.Like a
timing chain,the belt rotates the camshaft in same direction as the crankshaft.Engine valves
allow the engine to breath.The intake valves open to admit air fuel mixture (air only in diesel
engines) to the engine cylinders.The exhaust valves open to allow burned gases to exit or
exhaust from the engine cylinders.Cams on the rotating camshaft operate the valve
train,which opens the valves.In this production line,the camshaft of 2,5 DI(minibus) and 2,5
DI TURBO are manufactured.
Material of the camshaft used in this production is;forged steel.
OPERATION 10;
FRAIZER 1 CENTERDRILLING AND MILLING MACHINE is used in this
operation.
Operation Definition: Milling of end faces and center drilling of each end.
(front end=left end) , (rear end=right end)
The camshaft is fastened to the fixture like the above position by operator and it is
stationary during operation(feed motion is done by cutting tools and center drills). Initially,
centerdrilling operation is done.Different size centerdrills are used at front and rear end
faces.The diameter of the center drill used at front end is larger than the one used at rear
end.The diameter of the centerdrill used at the front end is 10mm,at rear end is 10,5mm.At the
front end most of chip is removed by centerdrilling operation and littlework is left to the
milling operation so one insert(cutting tool) is sufficient for milling operation at the front
end.But at the rear end,centerdrill is smaller than the one at the front end.As a result of

29

this,little amount of chip is removed by centerdrilling operation and most of chip must be
removed by milling operation.Two cutting tools are used in this milling operation(there is one
insert at the left and two at the right).The cutting tools used at both end are same but only
diameter of centerdrills are different.The purpose of centerdrilling is;to support workpiece
effectively in the following operations.With milling operation,length of the all workpieces are
adjusted and became the same value.In this operation,mixture of multan(67/5) and water is
used as cutting fluid.
Cutting speed,feed rate and rotational speed in this operation are as follows;
Rotational Speed Cutting Speed Feed Rate
(rpm)
(m/min)
(mm/min)
Milling of front end
800
120
40
Milling of rear end
800
120
40
Centerdrilling of front end
800
25
40
Centerdrilling of rear end
800
25
40
OPERATION 20;
CSEPEL RADIAL DRILL is used in this operation.
Operation Definition: Drilling of pin hole at rear end.
The workpiece is mounted vertically by operator and supported with centers at both
ends.The diameter of the drill used in this operation is 100,2 mm.The distance between the
axis of camshaft and axis of this pin hole is 19mm.The angular position of this pim hole is not
very important.In this operation,workpiece is stationary and the drill is fed to the workpiece.
(this feed motion is not automatic,it is performed by operator). The essential purpose of
drilling this hole is;to fix the part to chuck in the next operations which provides
simultaneously rotation with chuck.There is no cutting fluid in this operation.
OPERATION 40;
MAZAK QT30 CNC LATHE is used in this operation.
Operation Definition: Turning operation(machining) of main bearings,front end,oil
channel and chamfering of main bearings.
In this operation,workpiece is held by the chuck from its rear end and front end is
supported with tailstock also workpiece is supported with centers from both ends.The
pin,which is fixed to chuck,fits into the pin hole at rear end which provides the rotation of
workpiece with chuck.Since length of the workpiece is more than 0,5m it is difficult to
support the camshaft due to centrifugal forces.So a mandrel(similar to follow rest) is used to
support the workpiece at the 3 rd main bearing.There is a turret which can hold 16 cutting
tool(insert).For different turning operations the turret is rotated and the related tool is brought
to cutting position.In this operation,5 different cutting tool(insert) is used.In this
operation,workpiece is rotated,tool is moved to and away from the workpiece and along the
axis of the work.The motion of the cutting tool is shown on the digital monitor the
machine.There is an alarm that warns the operator about the errors;like tool wear,lack of
coolant and wrong location of workpiece.The machine can be operated from the control
panel.There is a program input keyboard used for programming the machine.G-CODE

30

language is used for installing coolant,tool change,cutting and spindle speed,motion

programs.The machine is aided with a high work safety supporting systems that is nearly
impossible to cause an accident.In case of an emergency,the machine is automotically
stopped.The chips are collected and seperated from cutting fluid by magnetic
collectors.Cutting fluid tank is found behind the machine.There are filters that seperates the
fluid chip mixture.
After workpiece is mounted,the subprocesses are as follows;
i. 3rd(the one at the middle)main bearing is roughly machined then mandrel closes
and supports the workpiece.After, other main bearings(except 5 th) are roughly
machined.
ii. Face(1st main bearing face) and front end are roughly machined respectively.
iii. Front end and face are chamfered and finish machined and other main bearings are
finish machined.Also,5th main beraing is chamfered,roughly machined and finish
machined respectively.
iv. All main bearings are chamfered then mandrel is opened
v. Finally,oil channel is machined.
Different cutting tools are used in each subprocesses.
Mixture of bor oil and water is used as coolant in this operation.
OPERATION 50;
OTOSAN DRILLING MACHINE is used in this operation.
Operation Definition: Drilling of main oil gallery(hole).
The machine used in this operation is a horizontal type machine and camshaft is
mounted horizontally.There are two spindles,same two drills and two fixtures which are
similar to each other on this machine.In this operation,workpiece is stationary,drill is rotated
and moved into workpiece alog its axis.The diameter of the drill used in this operation
is;10,80,3mm.Workpiece is mounted to the 1st fixture at which workpiece is drilled to a
depth of 243,3 0,3mm along its axis from its front end.Then workpiece is mounted to 2 nd
fixture at which workpiece is drilled 247,30,3mm from its rear end along the axis of the
workpiece and operation is completed.
The drills are supported by bushing guides during the operation because drills are
long.There is some problem about chip removal in drilling long holes.To minimize this
problem, drills are moved out from workpiece after drilling some portion. In this operation,
mixture of bor oil and water is used as coolant and sprayed to outside of the workpiece.
OPERATION 60;
DOGANAY DRILLING MACHINE is used in this operation.
Operation Definition: Drilling of oil holes.
This is a vertical type drilling machine.Workpiece is mounted to fixtures in
horizontal position.The position of oil holes are determined according to pin hole position.The
fixture has pin and this pin fits into pin hole and the position of 5 oil holes are
determined.There are 5 seperate drills which are rorated by differnt spindles and these 5 holes

31

are drilled simultaneously with the vertical motion of the drills.The diameter of the drills used
in this operation is 4mm.Also angular position of the oil hole must not be coincident with the
pin hole at the 5th main bearing.
OPERATION 65;
CSEPEL RADIAL DRILLING MACHINE is used in this operation.
Operation Definition: Core drilling of front end main oil hole.
This machine is plain radial type drilling machine.These
type of machines provide only a vertical spindle motion.The
workpiece is mounted vertically.The main purpose of this operation
is; enlarging the diameter of the hole to 14mm and to a depth of
36mm and this operation causes to form obstacle at that point due
to diameter difference.No cutting fluid is used.
OPERATION 70;
CSEPEL RADIAL DRILLING MACHINE is used in this operation.
Operation Definition: Tapping of front end main oil hole.
Same machine is used as the previous one only,the drill
is changed and very little amount of cutting fluid(multan 67/5 +
water) is used.The diameter of the drill is 16mm and tapped to a
depth of 30mm.
OPERATION 80;
CSEPEL RADIAL DRILLING MACHINE is used in this
operation.
Operation Definition: Reaming of post end(main oil
gallery at both end is reamed).
The same machine is used as the previous one only, the
drill is chaged with reamer(type of the reamer used in this
operation is;straight fluted taper reamer).Same reamer is used
for both end.The diameter of the reamer is 11,87mm.The depth
of the reamed surfaces are;for the front end:43,5mm
for the rear end:8mm.
One obstacle is formed at front end main hole in
operation65 and after this operation another obstacle is formed
due to diameter differences and sealing ball is placed between
these
obstacles.
OPERATION 90;
SCHAUDT GRINDING MACHINE is used in this operation.

32

Operation Definition: Grinding of faces of main bearings.

Both workpiece and grinding wheel are rotated,meanwhile feed motion is done by
grinding wheel.Workpiece and grinding wheel are positioned that they are not perpendicular
to each other.The pin,which is fixed to chuck,is passed into the pin hole of the workpiece at
rear end and this provides the rotation of the workpiece with chuck and also workpiece is
supported with centers from rear and front ends.Starting from 1 st main baering all main
bearings are ground respectively.Grinding wheel is ground with diamond cutting tool,which is
part of the machine,after every operation.After the completion of operation,diameter of all
main bearings are checked whether it is in tolerances range or not.Mixture of multan and
water is used as cutting fluid.This operation takes nearly 8 minutes.
OPERATION 100;
CLICHY ANGULAR GRINDING MACHINE is used in this operation.
Operation Definition: Grinding of front end and face of 1st main bearing.
This operation is very similar to last operation.Mounting of the workpiece is same
with the previous operation.The grinding wheel and workpiece are positioned that they are not
perpendicular to each other.That provides the simultaneous grinding of two surfaces.Both
workpiece and grinding wheel are rotated by spindles meanwhile,grinding wheel feeds.Face
of the 1st main bearing is ground by the sideface of the grinding wheel,at the same time front
end is ground by the periphery of the grinding wheel.The grinding wheel is ground with
diamod insert after every 5 operation.The diameter of the grinding wheel used in this
operation is 760mm.Mixture of multan and water is used as coolant.
OPERATION 110;
RAMBAUDI CNC VERTICAL MILLING MACHINE is used in this operation.
Operation Definition: Milling of keyway.
Solid type milling cutter(diameter is 5mm) is used.The workpiece is mounted on
fixtures by operator and centers support workpiece at both ends.The workpiece is stationary,
milling cutter is rotated and moved along the axis of workpiece.The length of the keyway
(along the axis of the workpiece) is;12,50,75mm.The machine can be operated from its
control panel. By using G_CODE language,motion of the cutting tool is programmed.The
milling is done according to these settings.No cutting fluid is used in this operation.After this
operation;length,symmetry,width..etc. of the workpiece are checked.
OPERATION 120;
SCHAUDT CAM GRINDING MACHINE is used in this operation.
Operation Definition: Rough and finish grinding of cam lobes.

33

In this operation,rotational speed of the grinding wheel during rough and finish
grinding is different. Rotational speed of spindle during rough grinding is higher than finish
grinding.After every rough and finish grinding,the grinding wheel is ground by diamond
cutting tool.

Rough grinding
Finish grinding

Rotational speed Cutting

(rpm)
(m/min)
63
30
31
60

Speed Feed
(mm/min)
20
20

Rate

The workpiece is mounted to the chuck,which is clamped to pattern,from its front

end and each end of the worpiece is supported by fixed centers.(in other words,the workpiece
is mounted to the chuck from keyway and that provides the rotation of the workpiece.The
camshaft is correctly oriented via keyway.)There are 8 lobes which are at different angular
positions with respect to axis of the workpiece,for this reason it is very difficult to grind
lobes.The purpose of using this pattern is;to grind cam lobes effectively and easily.
Initially,workpiece is rough ground starting from rear end and all cam lobes are ground
respectively. Then,rotational speed of the grinding wheel is changed for finish grinding and
workpiece is finish ground with same sequence as the previous suboperation.During this
operation, mixture of multan(47/6) and water is used as cutting fluid.After operation is
completed,diameter of cam lobes are checked whether they are in tolerances range or not.The
cam lobe which is nearest to the front end is intake lobe,the one next to this is, exhaust lobe
and this continues in that sequence.(intake,exhaust,intake,exhaust.....)Diameter of the intake
and exhaust cam lobes are different.For each cam lobe,there is height differences between the
sideface which is near to the front end and the sideface which is near to the rear end in the
range of 0,032-0,02mm.
OPERATION 122;
TEZSAN LATHE is used in this operation.
Operation Definition: Machining of fuel pump eccentric.
This machine is an ordinary lathe but in this operation special fixture is used,which is
manufactured by OTOSAN,only for this operation.The axis of the fuel pump eccentric and the
camshaft are at different positions and as a result of this;to machine fuel pump eccentric
effectively, it is neccessary to rotate workpiece about the axis of the fuel pump instead of axis
of the camshaft.This special fixture provides the rotation about axis of the fuel pump
eccentric. The position of the workpiece on fixture is determined by the position of keyway.
(Camshaft is oriented correctly via keyway) Then,fixture is mounted to the machine
horizontally and is supported with centers from each end.A small piece is mounted to the
chuck in horizontal axis and to one side of the fixture in vertical axis.During rotation they
stick each other and rotate together.In this operation workpiece is stationary,feed motion is
done by cutting tool automatically.The main purpose of this operation is; to remove some
amount of chip before grinding operation and this provides very little amount of chip removal
for the following operation.

34

OPERATION 125;
LANDIS GRINDING MACHINE is used in this operation.
Operation Definition: Grinding of fuel pump eccentric.
The same fixture is used as the previous operation.This operation is very similar to
the previous one only difference is; in that operation workpiece is ground instead of
machined. Also, mixture of multan(47/6) and water is used as coolant.
OPERATION 140;
(HAND OPERATION);
Operation Definition:Flushing of main oil gallery and oil holes.
OPERATION 150;
GUNPAR WASHING MACHINE is used in this operation.
Operation Definition:Washing of workpiece.
Workpiece is washed the mixture of multan P3 5175 (% 5) and water.The
temperature of this mixture is 80C.After visual inspection, If there is no problem "OK" sign
is marked on workpiece surface.
OPERATION 160;
(HAND OPERATION);
Operation Definition: Assembling sealing balls to oil gallery.
Automatic press is used to assemble sealing balls into ends of the camshaft.The
depth(position of sealing balls from surface) is checked for every workpiece.The purpose of
using these sealing balls is; to prevent leaking oil.

REAR-AXLE PRODUCTION LINE

The rear axle being used to connect the wheels to differential gears is manufactured
in this production line.The rear axle is often suspended from the body or frame of the vehicle
by leaf springs attached to the axle housing.A rear axle performs several functions.These
include;
1) Changing the direction of drive shaft rotation 90 to rotate the axle shafts.
2) Providing a final speed reduction between the drive shaft and the axle shafts through the
final drive gears.
3) Providing differential action so one wheel can turn at different than the other,if necessary.
4) Providing axle shafts or half shafts to drive the rear wheels.
5) Acting as a thrust and torque reaction member during aceleration and braking.
Material of the rear axle is; forged steel
Hardness: 156-196 HB

35

Both LCY and LCX rear axles are manufactured. These two differs in length and
radius.For LCY its diameter of flange is smaller and diameter of shaft is larger than LCX.
LCXs are used in 70 ps and LCYs are used in 100 ps Ford Transit Vans. The operations of
turning,straightening,roll threading,induction hardening and drilling are done.
OPERATION 10;
HORIZONTAL DRILLING MACHINE is used in this operation.
Operation Definition: Center drilling,drilling of rotator holes and end cutting.
The machine(tables,fixtures,...) is completely product of FORD.
The axle is mounted on the table horizontally.The workpiece is fastened to fixtures
then hyraulic fasteners are used to fix the workpiece.The rotator holes are drilled on the
outside of the flange.These rotator holes are used to mount the axle correctly to the machines
in the following operations.Two rotator holes are drilled by 180 angle on the face of the
flange.Depth of the holes is nearly 50,25mm.On the face of the flange,only rotator holes and
center drills are drilled and no milling operation is performed.But at the right hand
side,workpiece is both drilled and also milled where two triangular inserts are fixed to tool
holder which also holds center.The purpose of milling is to bring the workpiece to desired
dimension(length).Centers(center drills) used at both end are same but only depth of center
holes are different. Bor oil is used coolant.
OPERATION 20;
MAZAK QT(QUICK TURN) 40 CNC LATHE is used in this operation.
Operation Definition: Rough and finish machining of flange and back face radii.
This operation is done by two different CNC machines;one is QT40 and the other is
QT30.
The axle is mounted to the chuck(horizontally) as shown in figure1 and it is
supported with centers from both ends.The axle is mounted to the machine from rotator holes
and this provides the rotation of workpiece.Since the workpiece is very long(nearly 1m),it is
very difficult to support the workpiece due to cenrifugal forces.So workpiece is supported by
three bushing guides(very similar to steady rest) during operation.The turret,which is part of
the machine,can hold 12(for QTN40) or 8(for QTN30) different inserts(cutting tools).For
different turning operations the turret is rotated and the related tool is brought to cutting
position.Turret is moved to and away from the workpiece and along axis of the workpiece.
The inserts are easily be taken off and changed.The operation takes nearly 8min.Mixture of
Multan(67/5) and water is used as cutting fluid.The motion of the cutting tool is shown on the
digital monitor of the machine.The machine can be operated from the control panel.There is a
program input keyboard used for programming the machine.Path of the cutting tool,the
changing time of inserts,cutting and rotational speeds.... are all programmed by using GCODE
language.

36

The chips are seperated and collected from oil by magnetic collector.There are filters that
seperate the oil chip mixture.Chip is continuos due to high speed of spindle and ductile
material.
In this operation 7 different cutting tools are used.(in rough and finish turning
operations different cutting tools are used)There are some subprocesses in this operations and
different inserts are used in each subprocess.
i. Initially,some potions(parts),which bushing guides(steady rest) support, of the
workpiece is rough machined and this is repeated for 3 times to remove enough
chip.At the end of this subprocess bushing guides are closed to support workpiece
effectively.
ii. The front face and periphery of the flange is roughly machined.
iii. The spindle(shaft) is completely machined and this is repeated for 3 times to
remove enough chip.
iv. The front face and periphery of the flange is finish machined.
v. The back face of the flange is machined.
vi. The part at which spindle connects to flange is machined
vii. The spindle end is machined.
OPERATION 35;
MAE HYDRAULIC PRESS is used in this operation.
Operation Definition: Straightening.
The machine is a vertical point press.Workpiece is mounted horizontally on two Vtype supports that only holds the workpiece(not clamp),and workpiece is also supported with
centers from each end.3 dial indicators are located along axis of the axle.One point on the
workpiece is taken as the reference point and then workpiece is rotated by operator with
hand.While it is being rotated the dial indicator gives data about the points it passes on.
The runout or eccentricity shown on the dial indicator is the amount the axle is bent
or out of alignment.If it is required load is applied on the nonlinear parts to obtain a whole
linearity. The amount of the load is adjusted by operator and the workpiece must be
straightened by pressing as low as possible.Then,the same operation is repeated until the
desired linearity is obtained.
OPERATION 40;
GROB ROLL THREADING MACHINE is used in this operation.
Operation Definition: Thread rolling of spline end.,
Thread rolling is a cold forming process operation in which the threads are formed
by rolling a thread blank between hardened dies to cause the metal to flow radially into the
desired shape.Because no metal is removed (there is no chip removal) in the form of chip,less
material is required,resulting in substantial savings.In addition,because of cold working,the
threads have greater strength than cut threads,and a smoother,harder and more wear resistant
surface is obtained.Also,the process is fast.Chipless operations are cleaner and there is savings
in material.There are two different methods in the rolling of threads.One of the method is the

37

one performed in this machine.Straight threads,lying at the front side parallel to the axis of the
axle,are cut. These threads enable the connection of the axle to differential gears.
Two rolling cylinders are located on the machine in vertical position at the cutting
edge.There are two cutter disks in the middle of these cylinders.The workpiece is held by
chuck from its flange side and the workpiece is supported with centers from both ends.The
workpiece is rotated in horizontal axis and moved to rolling cylinders which are rotated in
vertical axis(they are rotated in opposite directions).Depth of cut is determined by gap
between two cylinders.Eventhough it looks like a cutting operation there is no chip removal.
Cylinders are rotated at high speeds when compared with the rotation of the axle which
means,the chuck is given a lower speed according to rollers.In this operation 26 threads are
cut.The eccentricity is given on the cutting edge so that when the roller rotates,the cutter disks
move towards the cutting edge,exerts pressure on the workpiece and makes toolmarks on the
surface.The calibration is so well done that the teeth are exactly linear although the workpiece
rotates.The operation takes nearly 25-30 seconds.(Since cold forging is done instead of
cutting,the threads are stronger)
OPERATION 50;
(EMA INDUCTION HARDENING);
The shaft(spindle) of the axle is hardened in this machine by induction hardening
process which is particularly well suited to surface hardening.The workpiece is located
vertically on the machine,being its flange side below.2 workpieces are located simultaneously
on machine.A circular shaped inductor is passed over the radius of the axle shaft.A pin is
located inside the inductor.Alternative current is passed through inductor and a variable
magnetic field is obtained.Direction of the current on the workpiece changes continuously
because of the direction change of current on the inductor.Heating is done by this mean.The
amount of heat production depends on the frequency of the current.This produces high
strength surface.(Before this operation,workpiece is deburred.)The flange side is not
hardened.During heating,workpiece is quenched with osmanil.Hardness on the surface along
the rear axle shaft is; RC 55/60.Hardness at the depth of 4mm from surface is RC 45.
Hardness at the depth of 6,4mm from surface is RC 40.
OPERATION 60;
Operation Definition: Tempering.
The workpiece lacks good toughness and ductility,despite its geater stregth.A
subsequent heating,known as tempering,is usually required to restore some desired degree of
toughness at the expense of a decrease in strength and hardness.This process is time and
temperature dependent.50 workpieces are heated simultaneously in oven at 180C.This
operation takes nearly 95minutes. Hardness on the surface is; RC 55/60.Hardness at the depth
of 4mm from surface is RC 45. Hardness at the depth of 6,4mm from surface is RC 40.
OPERATION 70;
(HYDRAULIC PRESS)
Operation Definition: Straightening.
After induction hardening and tempering processes,workpiece may loose its
linearity.This operation is same with operation35.

38

OPERATION 75;
(KARL DEUTSH CRACK CONTROL)
Operation Definition: Surface crack control.
After induction hardening and tempering processes,there may be some cracks on the
surface of the axle and surface cracks are controlled with this machine.A current(whose value
is a800A) is passed through the workpiece.While current is passing through the workpiece,
mixture of Mag.flux concentrant and water (ratio:1:50) is sprayed to the surface of the
axle.This mixture fills the cracks on the surface.An ultra-v light is projected on the workpiece
and crack can be seen by naked eyes in the form of white lines.All workpieces are checked
and if there is no crack,the workpiece is machined up to finish,and others are rejected.
OPERATION 80;
CSEPEL HEID CNC LATHE is used in this operation.
Operation Definition: Finish turning operation of flange face and radius and
channels.
(4 different cutting edges are used.)
OPERATION 90;
OTOSAN HORIZONTAL DRILLING MACHINE is used in this operation.
Operation Definition: Drilling and reaming of flange holes.
This machine is a multi-spindle drilling machine.The axle is mounted to special
fixtures and supported by centers from both ends.2 suboperations are done.Initially,holes are
drilled(all holes are drilled simultaneously).Then,workpiece is mounted to another fixture and
flange holes are drilled and correct location is done by 2 pin holes machined in first step.For
LCX 5 holes and for LCY 6 holes are drilled and different chucks are used.The diameter of
the drill used in LCX is;12,3mm and the diameter of the reamer is 12,95mm.Bor oil is used
cutting fluid.(in this operation,workpiece is stationary and feed motion is done by drill.)
OPERATION 95;
(HAND OPERATION)
Operation Definition: Countersinking of flange holes.
OPERATION 100;
(HAND OPERATION)
Operation Definition: Deburring and cleaning.
OPERATION 110;
(HAND OPERATION)
Operation Definition: Final check.

39

FLY-WHEEL PRODUCTION LINE

The flyweel serves as the driving member of the clutch in cars with a manual
transmission. In addition,the flywheel has a ring of teeth on its outer rim.A small pinion gear
on the starting motor meshes with these ring gear teeth when the starting motor operates.This
rotates the flywheel and crankshaft to start the engine.
(Flywheel:On a vehicle with manual transmission,a heavy metal wheel attached to the engine
crankshaft which rotates with it;helps smooth out the power surges from the power strokes
and also serves as part of the clutch and cranking system.Flywheel Gear:A gear,fitted around
the flywheel,that is engaged by teeth on starting motor drive to crank the engine.)
Material of the flywheel is cast iron.
In this production line, 2,5 DIs,DOVERs,ZETEKs and 500Ks flywheels are
manufactured.
OPERATION 10;
DIEDESHEM VERTICAL CNC LATHE is used in this operation.
Operation Definition: Turning operation of clutch mounting surface.
In machining large and/or heavy parts vertical turret lathes are used.In this operation,
the flywheel is mounted to the rotary work table in horizontal position and rotated about
vertical axis(Workpiece is located horizontally on machine,being its crank mounting surface is
below).Path of the cutting tool,tool changing time,rotational speed..... are programmed by
operator on CNC machine.Feed motion is done by turret which can hold 12 cutting
tools.There are 4 suboperations.In the first two suboperations no cutting fluid is used,becuse
seramic cutting edge is used(Turning operations with ceramic cutting tool do not need
coolant).In the last two suboperation bor oil is used as cutting fluid.Cutting tools used in each
suboperation are different.Suboperations are as follows;
i. Clutch mounting surface(the surface with diameter 337,5mm) is rough machined.
ii. Sideface of the outer radii (periphery of the 337,5mm diameter surface) is rough
machined.This operation is repeated twice to remove enough chip.
iii. Clutch mounting surface and sideface of outer radii are finish machined.
iv. Crankshaft passing inside radii (the surface with 136mm diameter) is machined.
Rotational speed,cutting speed and feed rate in this operations are as follows;
Suboperations Rotational
(rpm)
1st
520
nd
2
470
3rd
565
th
4
280

Speed Cutting
(m/min)

Speed Feed Rate (mm/min)

550
500
600
120

OPERATION 20;
DIEDESHEM VERTICAL CNC LATHE is used in this operation.
40

130
94
102
42

Operation Definition: Machining of cranckshaft mounting surface pilot bearing hole.

This CNC is same with the machine used in the previous operation,only difference is
workpiece is mounted horizontally to the machine,being clutch mounting surface below.The
other face of the flywheel is machined in this operation.There exists 6 suboperations and in
each suboperation different cutting tools are used.Ceramic cutting tool is used in first 5
suboperations.
i. Circular radii and outer radii are chamferred and outer crank mounting surface is
roughly machined.
ii. Flywheel ring gear joint surface and outer radii of the flywheel is roughly
machined.This operation is repeated twice.
iii. Inside radii is roughly machined.
iv. Counter boring of outer radii.
v. Outer radii and crank mounting outer surface is finish machined.
vi. Cranck passing inside radii and flywheel ring gear joint surface is finish
machined.In this process hard metal cutting tool is used.
OPERATION 30;
HITACHI VK45 CNC SINGLE SPINDLE DRILLING MACHINE is used in this
operation.
Operation Definition: Drilling.
This is a vertical drilling machine with single spindle.In this machine there is a turret
which can hold a total of 8 drills+reamers+... For different operations turret is rotated and
related tool is brought to cutting position.Workpiece is mounted(horizontally) on the table that
the clutch mounting surface stays upward.Workpiece is stationary during operation but drill is
rotated and moved to(fed to) workpiece in vertical direction.Mixture of multan(67/5) and
water is used as coolant.Suboperations taking place in this operation are as follows;
i. Clutch mounting holes(there are 6) are drilled(to a depth of 23,5mm) and
chamfered.In this suboperation,special combined drill,which is 6,8mm in
diameter,is used.Holes are drilled one by one.
ii. Clutch mounting holes are tapped to a depth of 16mm.(=8mm).These clutch
mounting holes are equally spaced around a circle with diameter 273mm.(the
angular distance between two holes is 60)
iii. Clutch pin holes(3 holes) are drilled(to a depth of 10mm) with 7,5mm in diameter
drill and chamfered with a cutting tool.These holes have 120 angular distance
from each other and they are placed at the mid point of the arc which is connecting
two clutch mounting holes.
iv. Clutch pin holes are reamed.(to a depth of 7,34mm)
v. Crank pin hole(1 hole) is drilled with 9,1mm diameter drill and chamfered with a
cutting tool.
vi. Crank pin hole is completely reamed with a reamer which is 9,53mm in diameter.
vii. Crank mounting holes(8 holes) are drilled with an 11,1mm diameter drill and
chamfered with a cutting tool used in 5 th process.These holes are equally spaced

41

around a circle with diameter 63,5mm and there is 22,5 angle between pin hole
and nearest two crank mounting holes.
viii. Reference hole is center drilled with a 6,8 mm diameter drill.
ix. Adjusting hole is drilled with a 13mm diameter drill.
OPERATION 65;
(HAND OPERATION)
Other side of the all holes except adjusting hole are countersinked by operator with
using air tools.
OPERATION 80;
(RADYNE R800)
Operation Definition: Induction hardening and mounting of flywheel gear ring.
The main purpose of this operation is;to make flywheel ring gear;which is
manufactured at ouside the plant, hardened and tightly fitted around the 321,63mm diameter
portion of flywheel.Initially,the ring is placed on fixture and is hardened by induction heating
process and the radius of ring is also increased.This process takes nearly 20-22 seconds. Then,
flywheel is pressed on this ring.The flywheel is pressed in the position of crank mounting
surface being below.Mixture of osmanil(%3) and water is used as coolant.As a result of this
operation,hardness of the ring is increased.
OPERATION 90;
SCHENCK MASS BALANCER is used in this operation.
Operation Definition: Drilling of balancing holes.
Some problems about the axis of the workpiece may occur because of the casting.
Axis may be eccentric.The axis is corrected in this machine. The purpose of this operation is
to balance the rotation of workpiece.In other words,rotation axis and the mass center are made
to coincident at the same point by drilling holes on the clutch mounting surface.The
workpiece is mounted horizontally on machine from its crank mounting holes and is rotated
by operator. Then,the portion of the workpiece which causes unbalanced rotation is
determined by machine and this angular position is shown on the digital monitor of the
machine. After,workpiece is rotated by operator to this position and hole(s) is(are) drilled at
this position with 122mm diameter drill around 142mm radius circle.The depth of the holes
must not exceed 18,5mm.Then,same operations are applied until the desired balance is
obtained.
Diameter of the drill (mm)
12

Rotational speed (rpm)

280

OPERATION 100;
Operation Definition: Final check

42

Cutting speed (m/min)

10

PINION GEAR PRODUCTION LINE

In this production line 70 ps and 100 ps Ford Transit pinions are manufactured.
Material of pinion gear is forged steel.
OPERATION 10;
(CHURCHILL EM0096)
Operation Definition: Center drilling and milling of both ends.
The machine used in this operation has four spindles.Two of them are used for center
drilling,the other two are used for milling.Tool holder which is fixed to the spindle can hold
12 inserts(cutting tools) at each side.The diameter of center drills(at both ends) used in this
operation are same(=6,3mm) but depth of center holes drilled by these centers are different,
so diameter of center holes are different.
In this operation,workpiece is mounted horizontally to the fixture which is composed
of three parts and workpiece is stationary in this operation.Center drills are rotated and moved
along axis of the workpiece.But milling cutters are moved in vertical direction to axis of the
workpiece.Initially,length of the workpiece is brought to desired dimensions by milling
operation.
Center holes are used for correct center location of the workpiece in the following
operations.Two center holes are drilled on both sides of the pinion gear;one on the thread edge
and the other on the gear edge whose diameter is larger.Center drills used at both side are
different in diameter,also their rotational speed,cutting speed and feed rate are different.In
addition,rotational speed,cutting speed and feed rate of milling cutters used at bot side is
different as given in the following table.
The center hole with large diameter is the one at right side,
The center hole with small diameter is the one at left side,
Rotatinal
Speed (rpm)
Center drill used at right side
1800
Center drill used at left side
2045
Milling cutter used at right side
270
Milling cutter used at left side
280

Cutting Speed Feed rate(mm/min for milling)

(m/min)
(mm/rev for drilling)
35
0,5
32
0,58
170
1,85
176
2,1

This operation takes nearly 2,5min.No coolant is used in this operation.

OPERATION 20;
MAZAK QUICK TURN 40 CNC LATHE is used in this operation.
Operation Definition: Rough and finish machining of surface of the workpiece.

43

In this operation,workpiece is mounted on fixtures horizontally and supported with

centers from both ends,also 5 nails fixed on chuck are stuck to head side of the workpiece
which provides the rotation of the workpiece.There are 3 suboperations;
i. Back face of the head side is machined.
ii. Workpiece is rough machined completely.
iii. Workpiece is finish machined completely.
Different cutting tools are used in these suboperations.To reduce runout,operation is
stopped after 2nd suboperation and chips on workpiece and cutting tool are cleaned with air
tools,then machine is started again for the last operation.Mixture of multan(67/5) and water
mixture is used as coolant in this operation.
After,workpiece is mounted to another machine to make necessary measuremants
like; angles,diameter...etc.
OPERATION 25;
Operation Definition: Workpiece no(number),charge code of material(this is needed
for heating operation) are marked on workpiece.
OPERATION 30,40;
(ROTO-FLO THREAD ROLLING)
Operation Definition: Thread rolling.
Workpiece is mounted to fixture and supported by centers from both ends.The roll
forging appratus having threads made of HSS make the cold working process by moving in
opposite directions.These appratus are horizontally located long bars that can squeeze the
pinion between each other.One is above,the other is below the workpiece.While these long
bars moving in opposite directions the workpiece is rotated(rotation of workpiece is provided
by the opposite direction motion of these appratus) and thread rolled.There is no chip removal
and less material is needed.The gap between these bars determines the depth of thread and it
can be adjusted by changing the location of upper bar.
Mobil DT25 oil is used as cutting fluid to reduce friction which reduces tool wear.
The spline portion of the workpiece is fitted to flange.
OPERATION 60;
OERLIKON HYPOID GEAR CUTTING MACHINE is used in this operation.
Operation Definition: Hypoid bevel gears cutting operation.
Bevel gears,teeth on a cone are used to transmit motion between intersecting
shafts.The teeth are cut on the surface of a truncated cone.Hypoid bevel gears have a curved
tooth shape but are designed to operate with non-intersecting axes.The reason for using
hypoid gears on the pinion is to eliminate any shock or noise in its working.

44

In this operation;both workpiece and gear cutter are rotated.One tooth is cut by three
blades of cutter and there are 9 groups,which are consists of 3 blades,are spaced equally
around gear cutter.
Oil is used for cooling in high volumes.The mixture of chip and oil is seperated by a
magnetic collector.
OPERATION 65;
Operation Definition: Deburring of teeth.
After this operation,workpiece is sent to another area for heat treatment processes
and these treatments are explained at the beginning.
These heat treatments are as follows;
First,workpiece is put into furnace
Carburizing; it takes 8-10 hours and temperature of the furnace is 850C or
above.Then,part passes to another portion of the furnace automatically for quenching.
Quenching; the material is quenched into a mixture of oil and water at a temperature
of 90C-110C resulting in an increase in the hardness of the material. This process takes
nearly 2 hours.Then workpart is taken out from the furnace for washing operation.
Washing; the temperature of water is nearly 80C.Initially,water is sprayed on
workparts then,workparts are dipped into tank which is full of with water.
Tempering; The next process is the tempering of the workpiece to provide some
ductility.
Washing; The temperature of the water is nearly 80C and is sprayed on workpiece.
Heat treatment operations on workpiece is finished and sent back for next operations.
For some transmission gears also induction hardening is applied.
OPERATION 100;
(MEA PRESS)
Operation Definition: Straightening of the workpiece.
OPERATION 110;
TACCHELLA GRINDING MACHINE is used in this operation.
Operation Definition: Small and large bearing radii,shim standing surface and code
segment are ground. Workpiece and grinding wheel are positioned that they are not
perpendicular to each other.All these surfaces are ground at the same time(shape of the
grinding wheel is suitable to grind these surfaces at the same time).Mixture of multan and
water is used as cutting fluid.After every 4 or 5 operation wheel is ground by diamond cutting
tool.Cutting speed,rotational speed and feed rate are as follows;
Rotational speed (rpm)
3030

Cutting speed(m/sec)
50

45

Feed rate (mm/rev)

0,12

OPERATION 125;
Operation Definition: Surface crack control.
After heat teratment processes,there may be some cracks on the surface of the
workpiece and surface cracks are controlled.A current(whose value is a800A) is passed
through the workpiece.While current is passing through the workpiece, mixture of Mag.flux
concentrant and water (ratio:1:50) is sprayed to the surface of the pinion.This mixture fills the
cracks on the surface.An ultra-v light is projected on the workpiece and crack can be seen by
naked eyes in the form of white lines.All workpieces are checked and if there is no crack,the
workpiece is machined up to finish,and others are rejected.
OPERATION 130;
Operation Definition: lapping of pinion and ring gear.
During this opertaion mixture of special oil and emery powder is used as fluid.
OPERATION 140;
Operation Definition: Washing.
Pinion is washed with mixture of 5175 Henkel and water.The temperature of this
mixture is nearly 40C.
OPERATION 170;
Operation Definition: Pinion and ring gear are paired and then same numbers are
marked on workpieces.Then, pinion is again washed same as the previous operation.
OPERATION 200;
Operation Definition: Final check.

CONCLUSION:
Before this summer practice, what benefits can be taken by such kind of an
experience was not known. This was thought to be as some kind of waste of time but the time
spent in OTOSAN became a great experience not a waste.
OTOSAN is a company from which a mechanical engineer student can benfit at a
maximum level. The practical experience of the courses, mentioned in the introduction part,
can be applied in all stages of the production. Witnessing every processes in the
manufacturing of parts,observing,touching,examining all the stuff that had been taught in
mechanical engineer courses was a great feeeling. By the help of this practice, the knowledge
gained in mechanical engineering courses, that were taken, was understood better.
A practice in OTOSAN teaches the student everything about automotive industry.
The students who have completed four weeks in engine department were the lucky ones, since
it gave them many opportunities to learn more about the internal combustion engines. Also the
plant has powerful machine tools, such as the CNC machines which provide lots of
advantages to firm such as less labor,less time,more accuracy and better quality.Which all
means, a very fast production with less effort. A summer practice in OTOSAN therefore may
be worth spending four weeks, since it is plant full of mechanical engineering applications.
One of the things that can be appreciated most, was the importance of training in
OTOSAN. There is continuous training to employees in many aspects.
46

This summer practice is definitely very useful for the mechanical engineering
student, because theories that we learned in courses are supported and strengthened with the
observations and practical experiences. In this practice not only technical aspects but
important things about real life and working conditions of a mechanical engineer was learned.
To sum up, summer practice is a great chance for an engineering candidates to gain a different
point of view about engineering.
Some recomendations:
In engine testing rooms testing of one machine nearly takes 45 min. And I think this
time must be reduced with modernization of these rooms. In foreign plants this testing
operation takes nearly 20 min. When compared with foreign plants 25 min. is wasted per
engine and this is a large amount of time. If this improvement can be achieved then
production rate can be increased incredibly.

COST ANALYSIS
COST ANALYSIS OF CONNECTING ROD
Direct Material
Indirect Material
Indirect Labour
Direct Labour
Energy
Amortization
Other Expenditure

2204408080 TL
179215000 TL
415629600 TL
136985200 TL
190156800 TL
159842280 TL
82658410 TL
______________________+
3368895370 TL

With this expenditure, the number of parts that is manufactured is 75.Thus, the cost of a cam
shaft is;
3368895370/75 = 44918604 TL

COST ANALYSIS OF FLY WHEEL

Direct Material
Indirect Material
Indirect Labour
Direct Labour
Energy
Amortization
Other Expenditures

62962965840 TL
396814409 TL
59878924 TL
314302937 TL
26598236 TL
56984213 TL
56321458 TL
_______________________+
63873866020 TL

47

With this expenditure, the number of parts that is manufactured is 500. Thus, the cost of a fly
wheel is 63873866020 / 500 = 127747732 TL

PLANT
MANAGER

ASST. PLAN
MANAGER
(TRUCK)
PRODUCTION PLAN
MANAGER
TRUCK AREA
MANAGER

ENGINE AREA
MANAGER

PRODUCT AND
PROCESS
IMPROVEMENT TEAM
LEADER

TRANSMISSION AREA
MANAGER

RECEIVING INSP.
TEAM LEADER

MANUFACTURING
ENG. MANAGER

QUALITY ASSURANCE
MANAGER

ACCOUNTING & ADM.

MANAGER

FACILITIES
MAINTANANCE TEAM
LEADER

48