1. DESCRIPTION OF THE COMPANY

TURKISH AEROSPACE INDUSTRIES ( TAI )Akıncı /ANKARA

TAI was established in 1984 by American company General Dynamics and TUSAŞ for the purpose of developing complete aerospace systems, primarily to meet the needs of Turkish Armed Forces. In 1991 Lockheed Martin took over the shares of General Dynamics Inc and now the share distribution is as follows:

49.0 % TUSAŞ 42.0 % Lockheed Martin of Turkey Inc7.0 % General Electric International 1.9 % Turkish Armed Forces 0.1 % THK

TAI is located on an area of 2.3 million square meters with an industrial facility of 160.000 square meters under roof. The total number of employees is 1700 with 402 engineers employed. (For detailed staff information see Appendix A.1.)

1.1. History of TAI

The first project of the company was F-16 production for Turkish Armed forces as a result of an offset agreement. The production began in 1987 as assembly, only when foundations completed 2 years later, manufacturing started. Between 1987-1999, as two projects, a total of 278 F-16 are produced and delivered, 46 of which, were for Egyptian Government.

In the following years, TAI produced 28 units AS 532 Cougar helicopters and 50 units CN-235 light transport airplanes for Turkish Armed Forces again in the framework of offset agreements. But these agreements were insufficient; therefore the management looked for ways to create new business areas and the company started to manufacture parts for leading aerospace firms like Boeing, Airbus, Sikorsky and Eurocopter.

1.2. TAI 2003

Today, in TAI approximately 30,000 units of pieces are being manufactured for 55 and the Company has been participating in the design and development activities of the Military Transport Aircraft (A400M) with leading European aerospace companies, Furthermore, TAI is the prime contractor of the Turkish Armed Forces Attack Helicopter production program.

1.3. Organizational Structure of TAIsee Appendix A.2.

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2. INTRODUCTION

The objective of the summer practice program ME 300 is to make the students get acquainted with different production techniques in a factory and by observing these processes in application, let them convert the theoretical knowledge learned in ME 202, manufacturing technologies and ME 114 technical drawing courses into practical knowledge. Also, in this time, students would have the opportunity to get familiar with work discipline and organization in a company, learn how a factory woks and more importantly, understand an engineer’s role in production.

3. PRODUCTION TECHNIQUES EMPLOYED IN TAI

TAI has a wide variety of manufacturing capabilities to produce aircraft and helicopter detail parts which require high technology production techniques. These techniques are classified and explained under certain headings below:

Chip-Type Machining Sheet Metal Fabrication Welding Chemical and Metallurgical Processes Composite Manufacturing and Metal Bonding

3.1. CHIP-TYPE MACHINING

Aircraft and helicopter detail parts, large-dimensioned and complex tooling parts are machined in the Chip-Type Machining Facility. Various steel parts, aluminium and titanium casting and forging parts, which require high precision and difficult machining processes, are also machined for other companies. Principal machining operations are: turning, milling, drilling and grinding. This Facility is composed of three main shops namely: First Cut, Conventional Machining and CNC Machining.

3.1.1. First Cutting

First Cutting is the place where initial machining operations are made. After inspection, raw material is cut to a rough size and sent for further machining. While cutting, grain direction is of great importance, if ignored can cause serious problems. Here sawing, shearing and flame cutting operations are performed. (For detailed information about equipment see Appendix B.1.1.1.)

Sawing is a basic machining process in which chips are produced by a succession of small cutting edges, or teeth, arranged in a narrow line on a saw blade. Each tooth forms a chip progressively as it passes through the workpiece, and the chip is contained within the space between two successive teeth until these teeth pass from the work. Because sections of

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considerable size can be severed from the workpiece with the removal of only a small amount of the material in the form of chips, sawing is probably the most economical of the basic machining processes with respect to the waste of material and power consumption, and in many cases with respect to labor.

Saw blades are made in three types namely hacksaw, bandsaw and circular saw. The first, Hacksaw blade is straight, relatively rigid, and of limited length with teeth on one edge. The second is sufficiently flexible so that a long length can be formed into a continuous band with teeth on one edge, and these are known as Bandsaw blades. The third and the last is a rigid disk having teeth on the periphery, these are called circular saws.

The sawing machines are grouped into three categories according to blades used, and in TAI, there are sawing machines from all these three categories.

Shearing is the mechanical cutting of materials without the formation of chips or the use of burning or melting where cutting blades are straight. The material used is mainly in plate or sheet form.

Flame Cutting is used primarily to cut sheets and plates. When ferrous metal is cut, the process is burning of iron at high temperatures. Because the reaction doesn’t occur until the metal is at approximately 870°C, an oxyfuel flame is first used to raise the metal to temperature at which burning will begin, then a stream of pure oxygen is added to the torch to oxidize the iron. The liquid iron oxide is then expelled from the joint by the kinetic energy of the oxygen gas stream.

3.1.2. Conventional Machining

In this shop, small dimensioned structural aircraft parts and tool details are machined. Turning, milling, drilling, and grinding operations are performed here. There are several conventional turning, milling, drilling and grinding machines, three CNC turning machines and one CNC jig boring machine. (See Appendix B.1.1.2. for detailed information about equipment in Conventional machining area)

3.1.2.1. Turning Operations

Turning is one of the basic machining processes; it is the process of machining external cylindrical and conical surfaces. The workpiece is rotated into a longitudinally fed, single point cutting tool. If the tool is fed at an angle to the axis of rotation, an external conical surface results. This is called taper turning. In form turning, a tool of specific form is used, in this way the shape of the surface is determined by the shape and the size of the cutting tool. Turning operations are usually performed on a machine called a lathe in which the tool is stationary and the part is rotated. Also facing and parting operations can be operated in these lathes. Facing is the production of a flat surface as the result of the tool being fed across the end of the rotating workpiece, usually used to finish the ends of the work. In parting, the tool is fed all the way to the axis of the workpiece causing it to be cut in two.

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Although Drilling and boring operations can be performed in lathes, it’s more suitable to discuss them later independently as they constitute an important part in chip-type machining processes and there are other specialized machines for these types of machining.

In Conventional Machining shop there are three CNC turret lathes, two turret lathes and one engine lathe and two second operation bench lathes for turning operations.

Second operation bench lathes are compact lathes with low spindle speeds; they are used for small jobs. Engine lathes doesn’t have numerical control, generally used for turning parts for which an operation may require long times; thus reducing the work on NC machines. The time required for changing tools and for making measurements on the workpiece is too much, that parts that require few operations are preferable. In turret lathes a longitudinally feedable hexagon turret replaces the tailstock thus solving this time problem to a great extent.

There are 3 CNC lathes in the area, a Mazak quickturn 35, Takisawa CNC turret lathe and Colchester Combi 4000. Tool movements, speed and feed rates are programmed and loaded into lathe’s computer through a network. Even with the Mazatrol program in Mazak, the process can be simulated, further with the monitor, the operation can be watched step by step.

3.1.2.2. Milling Operations

Milling is a basic machining process by which a surface is generated by progressive chip removal. Sometimes the workpiece is fed into a rotating cutting tool, while most of the time cutter is fed to the stationary workpiece.

Milling operations can be classified into three categories: peripheral milling, face milling

and end milling.

In peripheral milling the surface is generated by teeth located on the periphery of the cutter body. The surface created is parallel with the axis of rotation of the cutter.

Face milling is a process that is used to generate flat surfaces on parts. The axis of rotation of the cutter is perpendicular to the machined surface. When face milling is used to produce small depths-of-cut for the purpose of creating smooth flat surfaces it is called skin milling.

End milling is the most versatile form of milling. An end mill usually consists of a cylindrical cutter that has multiple cutting edges on both its periphery and its tip. Due to the interrupted nature of endmilling, these cutting edges, or flutes, are usually made helical to reduce the impact that occurs when each flute engages the workpiece. Depending on the nature of the feature to be machined, the axis of rotation of the end mill may be either perpendicular or parallel to the finished surface. The peripheral cutting edges generate a finished surface parallel to the axis of rotation, and the end cutting edges produce a finished surface perendicular to the spindle.

In conventional machining shop, universal 3-axis milling machines are used for milling. On these machines mostly, skin-milling and end milling operations are performed. The pieces that will be machined in CNC milling machines usually skin-milled here to be fixed properly and end-milling is done most of the time, to make fixtures or remove tabs from workpieces already machined in CNC machines. Because in aircraft industry, parts usually

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require high precision machining and extreme surface finish, CNC milling machines are prefered for most operations.

3.1.2.3. Drilling & Boring Operations

Because of the most equipment in conventional machining area are designed to perform both operations, it is suitable to discuss them under the same heading.

Drilling is a very important process performed to make holes. Of all the machining processes performed, drilling makes up about 25%. Most drilling is done with a tool having two cutting edges. These edges are at the end of a relatively flexible tool. Cutting action takes place inside the workpiece and most of the time the only exit for chips is the hole that is filled by the drill.

In conventional machining shop, drilling can be done on a variety of machines including lathes, universal milling machines, jig borers and drilling machines which are designed and used primarily for drilling. There are two types of manual-controlled drilling machines in the conventional machining area. The first one, a radial drilling machine is used for large workpieces that cannot be easily handled manually. This machine has a large, heavy round, vertical column supported on a large base. The column supports a radial arm that can be raised and lowered by power and rotated over the base. The spindle head, with its speed and feed-changing mechanism, is mounted on the radial arm. It can be moved horizontally to any desired position on the arm. The second one, box-column bench drill is used to make holes up to 0.5.in in diameter. It has a column of box type construction.

Boring is essentially internal turning while feeding the tool parallel to the rotation axis of the workpiece. It always involves the enlarging of an existing hole, which may have been made by a drill or a result of a core in a casting. Boring operations can be performed in special boring machines as well as lathes. Jig borers are very precise vertical type boring machines. There are 6 manual controlled jig boring machines and one CNC jig-borer in conventional machining shop, capable of boring operations.

3.1.2.4. Abrasive Machining Operations

Abrasive machining is a material-removing process that involves the interaction of abrasive grits with the workpiece at high speeds. The chips that are formed resemble those formed by other machining processes. The results that can be obtained by abrasive machining range from the finest and smoothest surfaces produced by any machining process, in which very little material is removed to rough, coarse surfaces that accompany high material-removal rates. Two most common abrasive machining operations performed in TAI are grinding and honing.

3.1.2.4.1. Grinding Operations

Grinding is the most common abrasive-machining process wherein the abrasives are bonded together into a wheel. Grinding can be used on all types of materials. The performance of grinding wheels is greatly affected by the bonding material and the arrangement of the abrasive particles. In grinding, the chips are small but are formed by the

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same basic mechanism of compression and shear for regular metal cutting. The feeds and depths of cut in grinding are generally small while the cutting speeds are high.

TAI has the capabilities for cylindirical, centerless, surface and tool grinding.

In cylindrical grinding, the grinding wheel revolves at an ordinary cutting speed and the workpiece rotates on centers at a much slower speed. The grinding wheel and the workpiece move in opposite directions at their point of contact. The depth of cut is determined by infeed of the wheel or workpiece. In the area there are two types of cylindrical grinding machines: an internal grinding and a universal grinding machine. Internal grinder is used chiefly for finishing round holes.

Centerless grinding makes it possible to grind both external and internal cylindrical surfaces without requiring the workpiece to be mounted between centers or in a chuck and this eliminates the need for center holes in some workpieces and the necessity for mounting the workpiece thereby reducing the cycle time. There is a Cincinnati centerless grinder machine in the area for this process.

Surface grinding machines are used primarily to grind flat surfaces. In the area there is a vertical surface grinding machine with reciprocating table on which the work is held by a magnetic chuck.

There are a variety of tool grinding machines in TAI. A wide range of cutter and tool grinding operations such as radius, drill, saw, counter and monoset grinding can be done.

3.1.2.4.2. Honing

Honing is an abrasive machining process that uses fine abrasive stones to provide accurate dimensions and excellent finish. Cutting speed is much lower than that of grinding. The process is used to size and finish bored holes, remove common errors left by boring or remove the tool marks left by grinding. Virtually all honing is done with stones made by bonding together various fine article abrasives, these stones are often equally spaced the periphery of the tool.

3.1.3. CNC Machining

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

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3.1.3.1. CNC Programming In TAI

The procedure is basically as follows: All machine functions required to fabricate a part properly are programmed and converted into machine’s language, then this functions are loaded as input to the machine.

There is a unit built for NC programming in TAI equipped with high technology computers using CAD/CAM and mostly solid modeling processing systems such as CATIA and Unigraphics. The purpose of these programming systems is to take programmer’s specified information and convert into a file called a centerline data file (CL file). The CL file contains information about part geometry, the tool paths to be developed along with commands indicating when to turn the spindle on or off, turn the coolant on or off, turn on cutter diameter compensation, and so on. (for a sample CL file see Appendix B.2.) Then a system called postprocessor is used to convert the CL file’s information into the tape commands that the NC control needs. The CNC shop has a variety of NC controls and a separate postprocessor is required for each machine control. The post processed information is loaded into machine through a network. But before beginning production usually a prototype part is created to verify that program does the required job properly.

On these machines, sometimes the machine tool operator performs short programming steps right at the console of the machine, programming some processing steps for the part directly into the computer memory.

In Aerospace industry contouring is extremely important, and most CNC machines in this area provide this feature. The required curves and contours are generated approximately by a series of very short, straight lines or segments of some type of regular curves, such as hyperbolas. This is called interpolation. The program fed to the machine is arranged to approximate the required curve within the desired accuracy.

3.1.3.2. CNC Machine Shop

This shop is equipped with large size numerical controlled machines. In this shop, large dimensioned complex aircraft parts and tools, that require 4 and 5-axis precise machining processes, are machined. There are three 5-axis, 3-spindle NC profilers, three 5-axis machining centers, two 4-axis horizontal machining center, eight 3-axis vertical machining centers one 4-axis and one 3-axis horizontal boring mills.( For detailed information about equipment see Appendix B.1.1.3.)

CNC machine tools in the area can be grouped as follows:

1. Profiler Mills: There are 3 Cincinnati Milacron 3-spindle 5-axis profiler mills in the area, capable to perform a wide variety of milling, profiling and tapering operations on simultaneously 3 parts. Mostly used for large complex pieces. They have 5-axis motion in tool with 25 degree travel in A and B axes. Because all axes motion is in tool, NC programming for this machine is fairly different from machines having worktables moving, in that the tool length gains more importance for this type of machining.

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2. Machining Centers: These are high technology, multi-axis CNC machines capable of milling, drilling and boring on multiple faces of a part at high horsepower and wider speed and feed ranges with tool magazines having tools up to 60 tools and some of them have automatic tool changer system. Machining centers are built in either horizontal or vertical configuration.

Horizontal machining centers tend to be advantageous for heavy box shaped parts while vertical machining centers are often preferred for flat parts that must have through holes. Fixtures for these parts are more easily designed and built for a vertical spindle.

3. Boring Mills: These machines are capable to perform boring, drilling, milling, reaming. There are two horizontal boring mills in the area: one 4-axis and one 3-axis.

3.2. SHEET METAL FABRICATION

In this shop, where aircraft detail parts are fabricated from mostly aluminium plates and extrusion material, metal forming capabilities are grouped into three main branches. (For detailed information about equipment see Appendix B.1.2.)

3.2.1. Forming Operations

There are various forming methods used in this area:

3.2.1.1. Stretch Forming Operations

Stretch forming is a metal forming technique that allows complex and severe bends in sheet without localized buckling or wrinkling. Stretch forming is used extensively in the aerospace industry to form large airplane parts.

A sheet of metal is gripped by two or more sets of jaws that stretch it and wrap it around a single form block. Various combinations of stretching, wrapping and motion of the block or grips can be employed, depending on the die and machine.

Most of the deformation is induced by the tensile stretching; therefore the forces on the form block are far less than those normally encountered in bending or forming. Consequently, there is very little springback, and the workpiece conforms very closely to the shape of the tool.

Stretch forming operation is probably one of the most performed operations in the area; After heat treatment, these forming operations should be applied in 30 minutes otherwise they are sent to refrigeration.

There are two sheet stretch forming machines in the area: A stretch form press with 750 tons capacity and stretch draw press with 400 tons capacity.

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In stretch form press, the male die moves to provide the main forming stroke.  Tension to the part is supplied by jaws (straight or curved) which pivot during the forming process.  The pivot of the jaws is adjusted and moves horizontally during forming to ensure proper tension in the part.

In stretch draw press, mating male and female dies are used to shape the metal while it is being stretched.

3.2.1.2. Sheet Metal Drawing

Sheet metal drawing is one of the most important and widely used manufacturing processes often used to make closed-bottom cylindrical or rectangular containers from sheet metal. When the depth of the product is less than the diameter, the process is considered to be shallow drawing. When the depth is greater than the diameter, it is known as deep drawing. There is a deep draw press in the area, capable of this operation.

3.2.1.3. Drop Hammer Forming

Drop hammer forming is an economical forming operation used to produce small quantities of shallow-drawn parts through the use of low-melting-point metal dies and a drop hammer.

Drawing on a drop hammer is considerably simpler than drawing with steel dies, but is often the most economical method for producing small quantities and it is most suitable for aluminium alloys therefore it is extensively used in TAI.

3.2.1.4. Fluid Cell Forming

Fluid cell forming also called flex-forming is based on the phenomenon that rubber diaphragm, when totally confined, acts as a fluid and transmits pressure up to 200 Mpa uniformly in all directions.

Compared with traditional forming techniques, fluid cell forming is said to be more flexible and economical. In addition to the precision of the process and the high quality of the end product, fluid cell forming offers shorter lead times from defined shape to finished part (cycle times are on the order of 1 to 3 minutes), while at the same time drastically reducing tool costs thus making this process attractive for prototype manufacturing and low-volume production up to about 10,000 identical parts. Also in Fluid cell forming, tools can be modified easily to accommodate design changes, and metal of different thicknesses can be formed on the same tool half, since no matching tool half exists.

There is a Quintus fluid cell press with forming pressure of 140 Mpa and a press force of 72,000 tons. It is used in forming medium size aircraft parts and is currently the highest pressurized hydraulic press in Turkey. This machine enabled TAI to acquire fabrication work of bodywork parts of Mercedes 403 Buses and some parts for Arcelik.

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3.2.2. Bending Operations

Bending is the plastical deformation of metals about a linear axis with little or no change in the surface area.

3.2.2.1. Angle Bending

Angle bending operations in the area are performed in Press Brakes. These machines are designed to make bends in heavier sheet, or more complex bends in thin material. These are hydraulically or mechanically driven presses with a long, narrow bed and short, adjustable strokes. The metal is bent between interchangeable dies that are attached to both the bed and the ram. Different dies can be used to produce many types of bends. The metal can be repositioned between strokes to produce complex contours or repeated bends.

There are 3 press brake machines in the area, and one of them is a hydraulic CNC press brake.

3.2.2.2. Roll Bending

Roll bending is a bending operation where plates, sheets and rolled shapes can be bent to a desired curvature on forming rolls.

These are used either to perform contours composed of straight-line elements on large parts or form parts requiring a large constant radius. There is a Haeusler sheet roller designed to perform these operations.

3.2.3. Cutting OperationsCutting operations in sheet metal area are limited to routing, drilling and shearing.

3.2.3.1. Routing

Routing operation is simply cutting and trimming of the sheet metal to a desired shape through the use of a template. A rotating cutter is often used to machine the part along the edges of the template.

This process can be done by small routers operable by hand as well as various capacity machines.

3.2.3.2. Drilling

Here drilling of sheet metal parts are performed by drill presses, mostly these machines are used for counter drilling operations and for hang holes that will be trimmed later.

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3.2.3.3. Shearing

Shearing operations in the area are mostly accomplished by punch presses. These machines have the capabilities of piercing, blanking, notching, trimming and punching. Basically as the punch pushes the workpiece, the metal responds by plastically flowing into the die. The applied stress exceeds the shear strength and the metal tears or ruptures through the remainder of its thickness.

CNC punch presses are particularly suited for low to medium quantity production runs. The fact that lead time from the completion of design to the production of parts can be extremely short is an important advantage. Larger production quantities are also economically run in the CNC punch press in many cases. When automatic loading and unloading equipment is employed, long periods of economical, unattended operations are possible.

There is a Trumpf Trumatic 2000R CNC punch press in the area having a linear magazine of 9 tool capacity and can machine sheets up to 6.4mm thickness. It has a hydraulic punching head with rotational axis functioning at 3 revolutions per second and it achieves stroke rates up to 900 hits in a minute. CNC programming is done by shop personnel by using AutoCAD. CNC programming procedure discussed before is followed here.

3.3. WELDING

Welding is a process by which two materials, usually metals, are permanently joined together by coalescence, which is induced by a combination of temperature, pressure and metallurgical conditions. Welding can be accomplished under a wide variety of conditions, and a number of welding processes have been developed.

Welding is not an appropriate operation to be used in aircraft production because of its high disadvantages over strength of materials therefore; in TAI welding has a limited use, and this operation is mostly based on Gas Tungsten Arc Welding.

3.3.1. Gas Tungsten Arc Welding

Gas Tungsten Arc Welding (GTAW) uses a nonconsumable tungsten electrode which must be shielded with an inert gas. The arc is initiated between the tip of the electrode and work to melt the metal being welded, as well as the filler metal supplied by a separate wire. A gas shield mostly Argon protects the electrode and the molten weld pool, and provides the required arc characteristics.

The process may employ direct current with positive or negative electrode or alternating current. In general, ac is preferred for welding aluminum. Direct current electrode negative is preferred for welding most other materials and for automatic welding of thick aluminum.

The process can be used to weld all types of joint geometries and overlays in plate, sheet, pipe, tubing, and other structural shapes. It is particularly appropriate for welding sections less than 10mm thick and also 25.4-to 152.4-mm diameter pipe.

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There is a weld cleaning system in the area used to clean aluminium for the preparation of welding by removing chip.

3.4. CHEMICAL AND METALLURGICAL PROCESSES

3.4.1. Chemical Operations

The chemical processing facility has the capability of high technology chemical operations and with its large capacity; it is one of the most advanced in Turkey.

The facility has various surface finishing systems providing cleaning such as vapor degreasing, the application of corrosion resistant coatings to aluminium and stainless steel parts, also more importantly chemical machining. The most used methods are discussed below.

Vapor Degreasing is a parts cleaning process that has been used in many applications for some years. Virtually aircraft flying today has components that have been vapor degreased. In TAI generally trichloroethylene is used as solvent.

Vapor degreasing is a relatively simple process. A heat source raises the liquid solvent to its boiling point. When the solvent boils, it produces hot, heavy vapors that rise to an established vapor line. At this point, the vapors are condensed on cold circumferential condenser coils, and the vapors rise no higher. Because the solvent vapors are heavier than air, they push the air above the vapor line. Parts at ambient temperature are then introduced into the solvent vapor, and the solvent vapor condenses on the part’s surface. The liquid solvent produced as a result of this condensation dissolves the greases and oils on the part and flushes them away. As the parts are cleaned, more vapors are produced in the boiling sump to replace those that were condensed.

Vapor degreasing can be applied to parts independently as well as in a series of processes before corrosion resistant coatings and chemical machining.

Chromic acid anodize coating is the most widely used coating operation providing excellent corrosion protection as well as a surface preparation prior to painting on aircrafts. Anodizing is carried out in acidic solutions where the part is made anodic and inert cathodes are employed to convert the aluminum surface to aluminum oxide. The coating grows inward from the surface producing a deposit with excellent adhesion.

Chemical machining also called etching is the simplest and oldest of the chipless machiningprocesses. In chemical machining, material is removed from selected areas of a workpiece by immersing it in a chemical reagent. Material is removed by microscopic electrochemical cell action, as occurs in corrosion or chemical dissolution of a metal; no external circuit is

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involved. This controlled chemical dissolution will simultaneously etch all exposed surfaces. The material-removal processing steps are discussed below:

1) Prepare: Vapor degreasing is followed by alkaline cleaning and rinsing to provide good adhesion for masking material. After rinsing operation water film breaking test is applied if passes the part is ready for masking operation.

2) Masking: The part is masked through immersing it again in the necessary chemical, then using a template the mask is peeled to leave the places that will be machined, open to etching.

3) Etching: The part is immersed it in a chemical reagent. If necessary part is rotated and the process is repeated.

4) Removing Mask: If the etching operation is accomplished as required, the maskant is stripped; the part is cleaned and desmutted if needed.

Etching is applied to large aluminium parts to reduce the weight and this facility is the only place where this operation performed in Turkey.

3.4.2. Metallurgical Operations

Various metallurgical operations are performed to develop the desired properties on alloys that make possible many of today's technological achievements. In TAI, these operations are applied mostly to aluminium sheet metal parts. Heat treatment of aluminium alloys are probably the most performed metallurgical operation in the area. The aim of this process is to improve the strength and hardness of the material.

Heat treatment is accomplished in two phases: solution heat treatment and then aging. In the solution heat treatment step, the aluminium alloy is heated to an elevated temperature to dissolve the alloying elements into solution. The metal is then quenched by immersing it into a water pool to “freeze” the atoms of the alloying elements in the lattice structure of the aluminum. This distorts and stresses the structure. In this condition, the alloys are still relatively soft but start to gain strength as the alloying elements begin to precipitate out of solution to form extremely small particles that impede the movement of dislocations within the material. When the formation of the precipitates is controlled by heating and holding the material at an elevated temperature for a period of time it is called artificial aging and this method is used frequently in TAI. By controlling the amount of precipitated particles within the aluminum, the properties can be controlled to produce peak strength or some combinations of strength and corrosion resistance.

TAI has also capability of shot peening. Shot peening is a surface treatment process used to introduce compressive residual stresses into ductile materials by localized deformation within the outer surface region. Small, hard particles (shot) having diameters within range of 0.1 to 1.0 mm are projected at high velocities onto the surface to be treated. The resulting deformation induces compressive stresses to a depth of between one quarter and one half of the shot diameter.

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3.5. COMPOSITE MANUFACTURING AND METAL BONDING

3.5.1. Introduction to Composite Materials

Many of our modern technologies require materials with unusual combinations of properties that cannot be met by the conventional metal alloys, ceramics, and polymeric materials. This is especially true for materials that are needed for aerospace applications. Today’s aircraft needs structural materials that have low densities, are strong, stiff, and abrasion and impact resistant, and are not easily corroded. Material property combinations and ranges have been, and are yet being, extended by the development of composite materials.

A composite, in this text, is a multiphase material that is artificially made, as opposed to one that occurs or forms naturally; thus most metallic alloys and many ceramics do not fit this definition because their multiple phases are formed as a consequence of natural phenomena.

In its most basic form a composite material is one which is composed of at least two elements working together to produce material properties that are different to the properties of those elements on their own. In practice, most composites consist of a bulk material, the matrix, and a reinforcement of some kind, added primarily to increase the strength and stiffness of the matrix. This reinforcement is usually in fibre form. Today, the most common man-made composites can be divided into three main groups:

Polymer Matrix Composites Metal Matrix Composites Ceramic Matrix Composites

Polymer Matrix Composites are the most common composites manufactured in TAI CAMB (Composite and Metal Bonding) facility. Also known as FRP - Fibre Reinforced Polymers (or Plastics) - these materials use a polymer-based resin as the matrix, and a variety of fibres such as glass, carbon and aramid as the reinforcement.

3.5.2. TAI Composite and Metal Bonding (CAMB) Facility

Composite and Metal Bonding (CAMB) Facility, covering an area of 10.500 square meters, started operating in 1994 to manufacture composite and metal bonding of CN-235 Light Transport Aircraft and of other products in future. With approximately 100 personnel in the CAMB facility, TAI is unique with its composite capabilities in Turkey. (See Appendix B.1.5. for equipment information)

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3.5.3. Composite Manufacturing Processes in CAMB

Composite manufacturing methods implemented at TAI comprise autoclave moulding, vacuum moulding, wet lay-up, hot compression moulding, polyurethane injection and Resin Transfer Moulding (RTM).

Wet lay-up is the oldest method used to manufacture composite materials. In this method, fibers are laid over a mould surface that has been coated with a release agent and resins are impregnated by using brushes into these fibers. But this lay-up method can be performed using preimpregnated reinforcement material called prepreg. The use of prepreg material eliminates separate handling of reinforcement and can improve part quality by providing more consistent control of reinforcement and resin contents. The use of prepregs has largely replaced the Wet lay-up method in TAI as it produces more desirable results. Prepreg lay-up method is only operable in the Clean Room, where temperature, humidity and dust particles are continuously controlled.

Also, lay up of adhesive-boned structures like prepreg honeycomb cores are performed in the Clean Room. These adhesive-bonded structures which contain bonded joints between skin sheets and low-density core material is called sandwich structures. When skin sheets are made of metal, then the process is metal bonding; in the process discussed here, prepreg skin sheets are used.

Prepreg parts must be kept in freezer before use. These parts taken from this freezer are sent for cutting operation. Cutting is accomplished on a CNC ply cutter machine. These pieces are forwarded to lay-up process. After lay-up, the composite parts must be cured. Curing takes place either in an oven or autoclave. Curing is often accomplished with vacuum bag molding, here a non-adhering plastic film, usually polyester, is sealed around the lay-up material and mold plate. A vacuum is slowly created under the bag forcing it against the lay-up. This draws out entrapped air and excess resin thus provides better adhesion. Vacuum bag molding is effective in producing large complex shaped parts.

Inspection follows curing operation; inspected parts are machined using water jet and diamond coated routers, when finished parts are forwarded to stock after a final inspection.

3.5.4. Metal Bonding

The metal bonding process, in which metal parts are adhesively integrated, is used to make a wide variety of aerospace structural parts such as flaps, spoilers, rotor blades, interior bulkheads and even entire wings. The process offers advantages, such as good impact resistance and repairability, as well as good strength-to-weight ratio, despite higher weight compared to composites-only structures. Adhesive bonding often enables designers to eliminate mechanical fasteners, which means a smoother part surface and better aerodynamic performance.

The Major disadvantage of the process is that the design is almost based on empirical data. Also the designer should have detailed knowledge about every separate material used in the process. Quality control techniques after manufacturing are so complex and costly;

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furthermore components manufactured especially through the use of honeycombs can cause corrosion in moist air.

3.5.4.1. Surface preparation

Most metal surfaces, in particular aluminum alloys, react with their natural environment to form complex interface. Aluminum in particular has a notable reactivity to oxygen. The longer a metal surface is exposed to its environment the more likely that it will be contaminated, and the less likely that it will meet the requirements of an adhesive-bondable surface. Thus, there is need for a surface treatment for application prior to bonding, to insure the success of that bonding.

The surfaces on which adhesive bonding will be applied must be very clean. In Aerospace applications, various surface treatment methods have been developed for different metals; but as in TAI CAMB facility mostly aluminium is used, we will consider the surface treatment for aluminium.

In TAI various methods are used for surface treatment processes including FPL etching, Chromic Acid Anodizing (CAA) and Phosphoric Acid Anodizing (PAA). Phosphoric Acid Anodizing is now and has generally been the preferred method of surface preparation for major aircraft primes. Boeing developed the process in the late 1960’s and the early 1970’s to improve the performance of bonded primary structures. Bonds formed with PAA-treated adheres exhibit more durability during exposure to humid environments that is superior to those formed with FPL-treated adheres. In addition, PAA bonds are less sensitive than FPL bonds to processing variables such as rinse-water chemistry and time before rinsing. As a result, the Phosphoric acid anodizing procedure has become the treatment of choice in the world aircraft industry for critical applications. Before anodizing various cleaning and rinsing operations are performed.

3.5.4.2. Curing Operations

Following phosphoric acid anodizing, primer is applied to prevent corrosion. These surface treated aluminium parts are cured in autoclave and sent to Clean Room. Here film adhesives are applied between two metal skins, vacuum bag is prepared and the parts are sent for curing in autoclave for the last time. Cured products are forwarded to stock.

4. SAMPLE WORKS

Workpiece A – 330A 21 2246 -21T – Airbus Fitting

Material : Aluminium 2024Condition : T351

After an inspection, the material in slab form with thickness of 25 mm is moved to the first cut section to be cut to a rough size by a vertical band saw, then this block of size 25 x 50

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mm (width x length) is moved chip-type manufacturing workcenter to be machined by a Okuma 3-axis vertical milling machine.

Fixed by a clamp system, on it’s 25 x 50 mm base, firstly outer surface is shaped into an elliptical form on the top view..

Then a T-shaped figure (on the front view) is created by milling the vertical excess material, thus a base of 3 mm thickness joined with a fillet of radius 2mm to the vertical part. The elliptical shaped base is mounted over an approximately 5 mm thick slab needed to fix the workpiece in the clamp

What is left is to shape the vertical rib; in this, the cutting tool moves along x axis, then y axis and z axis sequentially to hold the proper dimension. First stage is finished with this operation.

The excess material on the base (which is needed to fix the piece by the clamp) is to be removed, for this process the workpiece is turned upside down, and by using the tool machined particularly for this, the piece is fixed again by the clamp system.

With this process completed, the workpiece is moved to drilling area to drill a 6 mm diameter hole, with 2 chamfers (0.5 x 45°) on both sides by a jig-boring machine. The piece is fixed by the clamps, the vertical part on horizontal plane. The technician uses two cutting tools for this process, one to drill the hole and the other to make the necessary chamfer (there are various cutting tools with certain degrees).

The Workpiece is deburred, and then inspected for the following criteria.1) Dimensional requirements2) Surface roughness3) Surface integrity4) Surface Quality

Then forwarded to stock.

Workpiece B – 35-22965 0101A01 – Cover (CASA)

Material: Aluminium 2024Condition: T4

The material is a sheet metal with thickness 2 mm. After inspection sheet metal is moved to firstcut and shaped into 250 x 250 mm, then comes to sheet metal fabrication section, first to be bent by a sheet roller Haeusler to a constant radius of 375 mm, then the workpiece is machined by a Cincinnati drill press, drilling 4 hang holes with a diameter of 3mm. These hang holes are for the following chemical process which is “Etching”.

In Etching the Workpiece is hold by the hangholes and exposes to a chemical which removes 1 mm thick material from the unmasked surface.

After cleaning, mask is removed and it goes to inspection to be checked if the operation is completed as requested.

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The Workpiece is then moved to Hand Routing center, there it is shaped using a control tool. When finished, it is moved to another section where a routing machine (Tilting Spindle Shaper) is used to make the necessary chamfer of 30 degree.

After deburring, The Workpiece is inspected and sent to Painting; following the final inspection it is forwarded to stock.

Workpiece C – 233A3203-401 – Boeing Flight Deck Panel

Material : Aluminium 2024Condition : T3Initial dimensions:Sheet metalGage : 1.6mm Width: 1250mm Length: 1250mm

Following the first inspection, the material is sent directly to Sheet metal section to be machined by Trumpf Trumatic 2000R Punch Press. Here the plate is shaped into 35 pieces with dimensions 228.6 x 146.00 mm.

The shapes are cut-out starting from the smallest to larger; the tool usage is as follows:

1) B-7/10:Rund 4.20 – to shape 4.2 mm diameter circles.2) Oblon 6.50 x 3.25 – to shape elliptical figures (slots)3) A-3/10:Rund 5.55 – to shape 5.55 mm diameter circles4) C-8/10:Rund 6.53 – to shape 6.50 mm diameter circles5) H00018 (PCDl) – to make a special shape in one step6) a-1/5:Rund 12.7 – to make 12.7mm diameter circle 7) Recta 23.88 x 11.18 – to make rectangles of width x length(23.88 x 11.18) mm8) Round 49.75 – to make 49.75 mm diameter circle9) Rechteck 76.2 x 5 – to seperate pieces

When finished, the workpiece is moved to deburring, after this process it goes to inspection.Following inspection, workpiece is sent to chemical processing unit.Here, chemical film is applied to all surfaces of the workpiece, after chemical inspection the piece is painted and inspected for the last time and is ready for assembly.

Workpiece D – 330A210170-21 – Inner Fish Plate – Cougar

Material : Aluminium 2024 Condition: T3

After inspected, a large block is cut into a rough size of 240 mm length 25 x 25mm(width and gage) by a saw, and sent to chip-type manufacturing center.

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The Workpiece will be machined in a MAZAK 5 axis vertical high speed CNC machine. But some operations should be done to prepare the workpiece for machining.

First, one side of the block(25 x 240mm) is skin milled by an universal 3-axis milling machine to fix it properly into the fixture for further machining. During this process, gage is reduced to 24mm.

After skin mill, the workpiece is sent for drilling. At a Jig Boring machine 2 boring holes of dia. 6 mm aligned with 4 counter bores of 10 mm diameter are drilled (on both (25 x 240mm) surfaces) (D1)

Now, the workpiece is ready for machining in 5-axis CNC MAZAK machining center. The operation is accomplished in two stages:

1) The workpiece is fixed to the fixture on it’s skin milled surface (25 x 240mm) by two bolts.first, (2mm x 45 degree) chamfer is shaped, then 6 holes of 3mm diameter on one side(24 x 240mm) and 3.5 mm diameter 8 holes on the other side (25 x 240mm) are drilled to the depth of approximately 3.5mm.

2) The Workpiece is turned 180 degrees along it’s 240mm length axis and fixed; again (24 x 240 mm) side on vertical position. This time the inner excess material is carved out and the sides are machined; thus basically making a L-shaped figure with a fillet of 1.25mm radius joining the two perpendicular sides. Finally, the far ends of the long side where the workpiece is fixed to the fixture is machined, making them easy to separate from the main part (L-shaped part) in the following operation.

Excess parts are removed the workpiece is deburred, sharp edges are rounded and

following inspection, the piece is sent for chemical operations. (D2)

Here, chemical film is applied to all surfaces of material then it’s moved to another task center where strontium epoxy primer is applied. Following the final inspection the workpiece is forwarded to stock.

Workpiece E – 18D534-80211-200 – CASA – Reinforcement

Material : Aluminium 2024 Condition: T351

Following the first inspection, the 45 x 45 mm block is forwarded to first cut section. Here it is cut to the rough size of 190 x 45 x 45 mm by a saw and moved to chip type machining center.

Here one side of it (45 x 190mm) is skin milled by a universal 3-axis Cincinnati milling machine and sent to another task center nearby to be machined by a 3 axis CNC Hitachi vertical milling machine.

Machining is completed in two stages:

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1) The Workpiece is fixed by a clamp system on its skin-milled surface (45 x 190mm).First outer surface is shaped by a 15.95mm diameter cutting tool, then the tool is changed to a 3mm radius one and the excess material is taken, required fillets are made thus creating a 2mm thick rib extending from a rectangular solid prism. To shape the rib, the cutting tool moves along x axis, then y axis and z axis sequentially and the first stage is completed.

2) The Workpiece is turned 90 degrees (now the rib is on the horizontal plane) and fixed by a clamp system again, this time to empty the inner part of the rectangular prism. First with a drill, a hole is made wide enough for the cutting tool with 12.7mm diameter to enter, then with this tool of zero diameter, the hole is widened and the proper dimensions are made with a smaller diameter cutting tool.

The excess material on the base (which is needed to fix the the piece by the clamp) should be machined now. For this operation, it’s moved to a 3-axis universal milling machine.

When finished, the workpiece is sent to another task center for drilling operations to be made. Here, two 12mm diameter and eight 2.5 diameter holes are drilled.

Afterwards the piece is sent to deburring. When finished the workpiece is inspected and moved to vapor degrease operation center. Following this, chromic acid anodizing is applied and the workpiece sent for painting.

Here, following primer coating, polyurethane is applied. After the final inspection the workpiece is forwarded to stock.

5. COST ANALYSIS OF TWO SAMPLE PRODUCTS

5.1. Cost Analysis Method

This method applied here to analyse two sample products is simply based on the assumption that the five basic cost elements constitute the total charge for each product. Cost elements are basically expressed in rates (per hour), and with working hours known, the charge of a product can be roughly calculated.

Cost Elements:

Direct Labor Direct Material Direct Fringe benefits Other Direct Charges Indirect Costs

Direct Labor Cost: Direct employees report their working hours on work order basis through automated data collection system. To calculate direct labor charges for each work order, monthly actual labor rates are used.

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Direct Material Cost: Material releases to production are recorded to related work orders.

Direct Fringe Benefits Cost: This includes extra charges for labor such as: bonus, severance payment, social security premium, meal subsidy, transportation and paid leaves.

Other Direct Charges: These include: project special expenses like training expenses, business travel expenses.

Indirect Cost: Items included are:

Salaries, fringe and material charges that are not directly related with the produced part

Travel and communication costs Utility costs Office and operating supplies Outside services Tax

5.2. Cost Analysis of Workpiece D – Cougar Inner Fish Plate

Manufacturing steps and working time (approximately) for each are as follows:

(Working time of manufacturing engineering and industrial engineering department is not discussed in the table below; but it will be considered in the cost calculation)

OPERATIONSWORKING TIME

PER EACH PIECE (THEORETICAL)*

DESIGN 360min 24min

INSPECT 10min 10min

FIRST CUT 45min 3minPREPARATION (SKIN MILL&DRILL) 15min 15min

MACHINING(CNC) 35min 35min

DEBURRING 10min 10min

INSPECTION 10min 10min

CHEM FILM 60min 4min

COATING 15min 15min

INSPECTION 10min 10min

*15 parts will be manufactured in the first step; therefore the working time spent for each individual part should be considered in the cost calculation. For example: actual design time is 360mins but theoretically for each individual piece it is 360 / 15 = 24mins.

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1. DIRECT LABOR COST

Because labor rates of engineers and technicians are different, the working hours are separated for each.

EMPLOYEEDIRECT LABOR HRS LABOR RATE COST($US)

Engineer 1.00hr 8$/hr 8.0$

Technician 1.35hr 5$/hr 6.8$

TOTAL 2.35hr 14.8$

2. DIRECT MATERIAL COST

Mass: 415.5g / 0.4155 kgRate($/kg) of Al 2024 T3 temper: 9.5$/kg

Total Cost: 4.0 $

3. DIRECT FRINGE BENEFITS COST

Direct fringe rate is approximately 0.5$ per direct labor $ thus a total of 7.4 $.

4. OTHER DIRECT CHARGES COST

This has a rate of approximately 0.5$ per direct labor hrTherefore the cost is 1.2 $

5. INDIRECT COST

The indirect cost rate($/hr) can be accepted to be around 8$/hr Therefore the cost is 18.8 $

TOTAL COST OF WORKPIECE D

By summing the above costs we find the total cost: 46.2 $

5.3. Cost Analysis of Workpiece E – CASA Reinforcement

Manufacturing steps and working time (approximately) for each are as follows:

(Working time of manufacturing planning and industrial engineering department is not discussed in the table below; but it will be considered in the cost calculation)

OPERATIONS WORKING TIME PER EACH PIECE

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(THEORETICAL)*

DESIGN 240min 12min

INSPECT 10min 10min

FIRST CUT 60min 3minPREPARATION (SKIN MILL) 10min 10min

MACHINING(CNC) 70min 70min

DRILLING 10min 10min

DEBURRING 10min 10min

INSPECTION 10min 10minCHROMIC ACID ANDIZING 60min 3min

COATING 15min 15min

INSPECTION 10min 10min

*20 parts will be manufactured in the first step; therefore the working time spent for each individual part should be considered in the cost calculation. For example: actual design time is 240mins but theoretically for each individual piece it is 240 /20 = 12mins.

1. DIRECT LABOR COST

Because labor rates of engineers and technicians are different, the working hours are separated for each.

EMPLOYEEDIRECT LABOR HRS LABOR RATE COST($US)

Engineer 0.75hr 8$/hr 6.0$

Technician 2.00hr 5$/hr 10.0$

TOTAL 2.75hr 16.0$

2. DIRECT MATERIAL COST

Mass: 1065.8g / 1.065 kgRate($/kg) of Al 2024 T351 temper: 11.5$/kg

Total Cost: 12.2 $

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3. DIRECT FRINGE BENEFITS COST

Direct fringe rate is approximately 0.5$ per direct labor $ thus a total of 8 $.

4. OTHER DIRECT CHARGES COST

This has a rate of approximately 0.5$ per direct labor hrTherefore the cost is 1.4 $

5. INDIRECT COST

The indirect cost rate ($/hr) can be accepted to be around 8$/hr Therefore the cost is 22 $

TOTAL COST OF WORKPIECE E

By summing the above costs we find the total cost: 59.6 $

6. CONCLUSION

I consider the twenty days I’ve spent practicing in TAI, as a great contribution to my education on my way to be a mechanical engineer. First of all, I think I‘ve accomplished the objective of ME 300 as required. Especially The theoretical knowledge I gained through the course of ME 202 was of great use to me during this summer practice; for I was familiar with the terms and concepts I came across, therefore more quickly I’ve adapted myself into the subject; in addition I found the chance to get acquainted with new manufacturing techniques and observe what I’ve learned in ME 202 thus completing my theoretical knowledge in some ways. Also, technical drawing courses helped me to understand the CNC programming step more detailed in the manufacturing process of detail parts machined by CNC machine tools.

Work discipline in a factory was something new to me; I found the chance to observe the relations between technicians and engineers, an engineer’s approach to various situations, and also get acquainted with a factory organization.

I’ve also observed and understood the extreme importance of economic factors in all steps of production starting from design to assembly for all parts manufactured; and perhaps this was the most important lesson I’ve learned during my summer practice.

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APPENDIX A

A.1. STAFF INFORMATION

Elementary School: 128Secondary School: 69High School: 741Military: 7Technical: 573Other: 161University: 763High Technical: 96B.S.: 575M.S./Ph.D: 92

Engineering: 402Computer: 29Electric/ Electronics: 47Aerospace: 69Industry: 50Metallurgy: 26Mechanical: 145Civil: 2Chemistry: 15Physics: 5Other: 14

Economic and Administrative Sciences: 118Business Administration: 54Finance: 6Economics: 28Other: 30

Arts and Sciences: 94Physics: 20Chemistry: 6Mathematics: 12Statistics: 24Other: 32

Other: 149

Total: 1701

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APPENDIX B

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B.1.MAJOR EQUIPMENT

B.1.1. CHIP TYPE MACHINING AREA

B.1.1.1. FIRST CUTTING

Meteora Horizontal Saw

(often used to machine long blocks)

Band Saw Angle: 16’9’’ x 1’’1/2 x 0.0050’

Cutting Capacity (at 90 degree)…Max.Round (dia): 17’’3/4…Max.Square length: 17’’3/4 x 17’’3/4

Max. Cutting Length…for Single Index: 20’’…for Multiple Index: 180’’

Plate Saw 4’ x 12’

Spindle Travel (Longitudinal): 140’’Feed Rate: 0-15 fpm

Cincinnati Skin Mill

Table Capacity: 124’’ x 60’’Face mill diameter: 18’’Face Mill Inserts: 12 piecesSpeed Range: 1750-3500 rpm

Wellsaw Power Hack Saw

Capacity: 5’’x 7’’ – 16’’x20’’ / diameter of 5’’Shipping weight: 74kg – 318 kg (approx.)

Band Saw

Horizontal capacity: 35’’ ½Vertical capacity: 20’’Wheel diameter: 36’’Blade Width 0.3175 – 5.08Table size: 36’’x36’’Tilt capacity: 45°(Right) – 45°(Left)

Contour Band Saw

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Max. Work height : 12’’Band width Capacity 1/16’’ – 1’’Saw Band Length 122’’ – 128’’Table tilt: 45°(Right) – 45°(Left)

Cincinnati Shear Mechanical (2)

(used to machine sheet metals)Blade Length: 12’Capacity …¼’’ – mild steel…1/10’’ – stainless steel…¼’’ – aluminium…1/10’’ – titanium

Enco Plate Shear (2)

Blade length: 6’Capacity …Round: 7/16’’…Flat Bar: 1.75 x 3/16Plates: 40lbs

Kalamazoo Cut Off Saw 12’’

Drive Motor 5 HPCoolant system: 10 GalWheel diameter: 12’’Capacity:…Solid - 2-1/2" …Pipe - 3"

Kalamazoo Cut Off Saw 18’’

Capacity: …Solid bar: 3" …Pipe, other shapes: 4" Table: 16" wide x 28" deep Wheel diameter: 18" Vise, foot-operate chain Drive motor: TEFC, 3-phase 10 HP Shipping weight: 625 lbs.

Oxy Plasma Flame Cutter

Capacity:…steel: 8’’…aluminium: 6’’Tracing Dimensions 100’’x 20’’

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Cutting Dimensions 120’’x 65’’Number of Torches: 3 oxy + 1 plasma torchesTracing Speed: 4-62 in/min

B.1.1.2. CONVENTIONAL MACHINING

Mazak Quickturn 35 CNC Lathe

Motor: 40HP2-Axis CNC Universal LatheMazatrol Fusion 640T Control Swing Over Bed: 25.93"

Takisawa CNC Lathe

Swing Over Bed: 15.7’’Turning Diameter: 100mmTurning Length: 200mmTurret #: 12

Colchester Combi 4000 CNC Lathe

Max Swing - 554 swing in gap: 830mm Distance between centers: 2000mmSpindle speed: 18 - 1800 rpmTurning Diameter: 225mmTurning Length: 1000mm

Mazak Universal Engine Lathe

Swing over bed: 21’’Swing over cross slide: 13’’ 1/8’’Max. Distances btw Centers: 80’’Spindle Speed Range: 25-2000 rpm

Feeler Second Operation Bench Lathe (2)

Herbert Turret Lathe (2)Swing Over Head: 15’’Swing over cross slide: 8’’3/4’’Turret positions: 6Max Turning Length: 14’’Max Length of Work: 12’’

Cincinnati Universal Milling Machine (7)

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Pratt&Whitney Jig Borer

Table Working Surface: 24’’x55’’Table Longitudinal Travel: 48’’Table Cross Travel: 24’’Spindle Head Vertical Travel: 24’’Standard Feed Range Per Revolution 0.0005’’ – 0.010’’

Pratt&Whitney Jig Borer

Table Working Surface: 25’’1/2x43’’Table Longitudinal Travel: 39’’3/8Table Transverse Travel: 2’’Boring Head: 17’’3/8Drilling Capacity…Cast Iron: 2’’…Steel: 1’’1/2Max. Boring Capacity: 10’’

Moore Jig Borer (2)

Table Working Surface: 19,5’’x11’’Table Longitudinal Travel: 14’’Table Cross Travel: 10’’Spindle Head Vertical Travel: 10’’Standard Feed Range Per Revolution: 0.001’’ – 0.003’’

Devlieg Jig Mill

Table size: 48’’x30’’Distance From Table to Spindle: 36’’

Radial Drill

Spindle Travel: 15’’Head Travel: 70’’Arm Travel: 30’’Feed Per revolution: 0.0023’’ – 0.029’’Number of Spindle Speed: 18

Box-Column Bench Drill

Table Working Surface: 13’’x 46’’Table Longitudinal Travel: 48’’Table Cross Travel: 18’’Distance from Table to Spindle: 22’’Number of Spindle Speed: 12

Pratt&Whitney CNC Drill (Tape-O-Matic)

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Table Working Surface: 45’’x29’’Table Travel (Longitudinal): 40’’Table Travel (Transverse): 26’’Head Vertical Adjustment: 22’’Positioning Per Axis: 0.001’’Repeatability: 0.0005’’

Cincinnati Universal Grinder

Max. Swing Over Table: 14’’ 15/16Max. diameter of Grinding: 14’’ 15/16Max. distance between Centers: 48’’Regular Grinding Wheel diameter: 14’’

Cincinnati Internal Grinder

Max. Swing Over Table: 19’’1/2Max. Swing Inside Table: 24’’1/2Dist. Between Wheel and Chuck: 30’’

Cincinnati Centerless Grinder

Grinding Wheel dia.: 15’’ – 20’’Work Dia.: Range 1/16’’ – 4’’3/4Regulating Wheel Dia.: 9’’1/2 – 12’’

Vertical Surface Grinder

Magnetic Chuck Dia.: 66’’Swing Capacity: 84’’Max. Unbalanced Load on Chuck: 10000lbsGrinding Wheel Size: 36’’

B.1.1.3. CNC MACHINING

Cincinnati Milachron Profiler Mill (2)

5-Axis 3 SpindleWorktable: 160’’x720’’Max. Spindle Speed: 3600 rpmAxis Travel:X – 600’’ A - +/- 25°Y – 164’’ B - +/- 25°Z – 28’’

Feed X-Y: 200(in/min), Z: 60 (in/min)

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Cincinnati Milachron Profiler Mill (1)

5-Axis 3 SpindleWorktable: 120’’x 606’’Max. Spindle Speed: 4000 rpmAxis Travel:X – 606’’Y – 112’’Z – 28’’Feed X-Y : 200(in/min), Z: 60 (in/min)A - +/- 25°B - +/- 25°

Gidding&Lewis 5-Axis Horizontal Machining Center

Worktable: 32’’ x 32’’Max. Spindle Speed: 4500 rpmAxis Travel:X – 48’’Y – 42’’Z – 30’’No. of Tools: 48A – 110B - +/- 360

Makino 5-Axis Horizontal Macining Center

High Speed MachineSingle SpindleNo. Of Pallets: 2Worktable: 1000 mm x 1000mmMax. Spindle Speed: 15000rpmFeed: 16000 mm/minAxis Travel:X – 1500mm A - +10 / -100°Y – 1600mm B - +/- 360°Z – 1200mm

Mazak 5-Axis Vertical Machining Center

High Speed MachineSingle SpindleWorktable: 630mm x 500mmMax. Spindle Speed: 25000rpmFeed: 50000 mm/min

Axis Travel:X – 630mm

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Y – 765mmZ – 510mmA - +30/-120°C – 360°

Makino 4-Axis Horizontal Machining Center

High Speed MachineSingle SpindleWorktable: 630mm x 630mmMax. Spindle Speed: 10000rpmFeed: 30000 mm/minAxis Travel:X – 800mmY – 750mmZ – 770mmB – +/- 360°

Okuma 4-Axis Horizontal Machining Center

Single SpindleWorktable: 630mm x 630mmMax. Spindle Speed: 5000rpmFeed: 20000 mm/minAxis Travel:X – 1000mmY – 800mmZ – 750mmB – +/- 360°

Gidding&Lewis 4-Axis Horizontal Bore Mill

Worktable: 360’’ x 120’’Max. Spindle Speed: 2000rpmFeed: 200 in/minAxis Travel:X – 360’’Y – 103’’Z – 48’’B – +/- 360°

Gidding&Lewis 3-Axis Horizontal Bore Mill

Worktable: 144’’ x 60’’Max. Spindle Speed: 2000rpmFeed: 200 in/minAxis Travel:X – 144’’Y – 67’’

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Z – 36’’Gidding&Lewis CNC Jig Bore

Worktable: 80’’ x 40’’Max. Spindle Speed: 4000rpmFeed: 10000 mm/minAxis Travel:X – 80’’Y – 40’’Z – 40’’

Okuma 3-Axis Vertical Machining Center MX-45VAE(2)

Worktable: 760mm x 460mmMax. Spindle Speed: 7000rpmFeed: 15000 mm/minAxis Travel:X – 560mmY – 460mmZ – 450mm

Hitachi 3-Axis Vertical Machining Center (3)

Worktable: 1676mm x 560mmMax. Spindle Speed: 4000rpmFeed: 5000 mm/minAxis Travel:X – 1400mmY – 600mmZ – 550mm

Hitachi 3-Axis Vertical Machining Center VS60

Worktable: 1400mm x 600mmMax. Spindle Speed: 20000rpmFeed: 30000 mm/minAxis Travel:X – 1250mmY – 610mmZ – 550mm

Hitachi 3-Axis Vertical Machining Center VS80

Worktable: 2250mm x 8500mmMax. Spindle Speed: 20000rpmFeed: 20000 mm/minAxis Travel:X – 2050mmY – 860mmZ – 600mm

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Okuma 3-Axis Vertical Machining Center MC-60VAE

Worktable: 1530mm x 630mmMax. Spindle Speed: 5000rpmFeed: 13000 mm/minAxis Travel:X – 1250mmY – 630mmZ – 610mm

B.1.2. SHEET METAL

Cyrill Bath Stretch Forming Press

Die Table Tonage: 750 TonsDie Table Stroke: 82’’Die Table Length: 100’’Jaws Stroke :72’’Max.Dist. Between Jaws: 144’’

Cyrill Bath Stretch Draw Press

Press Ram Tonnage: 400 TonsLongitudinal Stretch Force: 250 TonsMax. Workpiece Size: 72’’x 144’’Max. Dist. Between Jaws: 160’’

Yucel Makina Deep Draw Press

Drop Hammers

Min. Die Area: 29’’x 25.5’’Max. Die Area: 90’’ x 40’’

Quintus Fluid Cell Press

Forming Pressure: 140MpaPress Force: 72,000 TonsMax. Tray Width: 10’’10/16Tray Area: 47’’4/16x118’’1/8Average Cycle Time: 150sec

Cincinnati Press Brake

Capacity: 150 TonsMax. Die Length: 12’’Bending Capacity: ¼’’x12’’

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Wysong Press Brake

Bending Capacity: 35TonsPunching Capacity: 20 Tons

Trumpf TrumaBend Press Brake(CNC)

Capacity: 150 Tons

Haeusler Sheet Roller

Roll Dia.: 3’’Max. Upper Roller Pressure: 100 TonsMax. Working Width: 12’’

GFM CNC Router

Max. Working Size: 57’’ x 151’’Spindle Speed: 5000-21000 RPM

Broken Arm Router

Table Size: 49’’x158’’Speed: 14400 rpmMax. Capacity: 5/8’’ thick Aluminium

Tilting Spindle Shaper

Table size: 40’’ x 60’’Spindle speed: 10000 rpmTilting Angle: 45°

Trumpf Trumatic 2000R CNC Punch Press

Max. Workpiece: Weight 75kgCapacity: 75 TonsMax. Sheet Thickness: 6.4mmTable size: 1270mm x 1270mmLinear magazine: 9 tool stations

Minster Punch Presses

Capacity: 75 TonsShut Height: 18’’x21’’Stroke Per minute: 90Max. Sheet size:17’’ x 30’’

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B.1.3. WELDING

TIG Welding Machines

300 Amper, AC, DCDimensions L 23’’W 36’’H 44’’

B.1.4. CHEMICAL & METALLURGICAL PROCESSES

Vapor Degreaser

Vapor Column: 60’’Storage tank capacity: 250 GallonsTank size: …Length…192'',…Width…30''…Height…80''Max. Load: 6000lbs

Aluminum Dipping Tanks

Length…6.1mWidth…1.2mHeight…3.1m

Steel Dipping Tanks

Length…1.8mWeight…1.2mHeight…1.8m

USF Schlick Shot Peening Blast System

Age oven

(For artificial aging of aluminium alloys)Size:…Length…6.1m…Weight…2.4m…Height…3.0mMax. Load capacity: 900kgMax. Temp: 260°C

Quench Furnace

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(For Solution heat treatment)Size:…Length…6.1m…Weight…1.2m…Height…1.9mMax. Load capacity: 1000 kgMax. Temp.: 593°C

B.1.5. COMPOSITE MANUFACTURING & METAL BONDING

Autoclaves

DimensionsAutoclave 1: 3.6mm Dia. X 14.0mLAutoclave 2: 2.0m. Dia. X 4.0m. LPressure 250 PsiTemperature: 4000 +/- 2 °CRate: 1-5C minute

Cure OvenDimensions: 2.0m.L x 2.5m.H x 4.0m.WTemperature 375 +/- 3CHumidity: 35 +/- 15%Electrically heatedEquipped with Vacuum System

Investronica CNC Ply cutting Machine

Gantry TypeL.7.2m x W.1.8mEquipped with Digitizing and Vacuum Table

Abrasive Water Jet Cutting Machine

Dim... 4.4 m.L x 1.3. m.H x 2.7 m.WWater Press 55,000 PsiFlow Rate : 6.8lt/minOrifice Dia.: 0.102 – 0.483 mm

Core Milling Machine

Dim... 3.5 m.L x 0.4m. H x 1.5 m.WGantry Type 4-AxisDigital ReadVacuum Hold Down

B.2. SAMPLE CL DATA FILE

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TOOL PATH/P1,STG-1-OPER-010----MSYS/0.0000,0.0000,0.0000,243.9997,-1.0000000, 0.0000000,0.0000000,0.0000000,1.0000000PAINT/PATHPARTNO/(MSG,PARTNO 330A210170 – 20)DISPLY/(MSG, T00000,MAZAK5X TAI MSTA1 MCDREV AA)PREFUN/21$$INSERT/G53G90Z0.$$INSERT/G53G90X0.04Y0.Z0.A0.C0.INSERT/G91G28Z0.INSERT/G91G28X0. Y0. A0. C0.PREFUN/17PREFUN/40PREFUN/49PREFUN/0INSERT/G91G28Z0.INSERT/G91G28X0. Y0. Z0.PREFUN/90RAPIDROTATE/AAXIS,ABSOL,0.0000RAPIDROTATE/AAXIS,ABSOL,0.0000LOAD/TOOL,15,Z0FF,147.0000INSERT/D15H15INSERT/643Z730.H15AUXFUN/43AUXFUN/46DISPLY/MSG,OPERATION 10 CUTTER 16MM CARBIDEDISPLY/MSG,CUTTET CARBIDE- 16X0.1MMSPINDL/RPM,20000,CLWCOOLNT/FLOODSELECT/TOOL,5$$ HIGH SPEED START$$ ROUGH-CUT USE “K85”INSERT/G61.1INSERT/,K99$$INSERT/G05 P2PAINT/ TOOL,NOMOREEND-OF-PATHTOOL PATH/STG-1-UST-2, TOOL, CARBIDETLDATA/MILL,16.0000, 0.1000, 75.0000, 0.0000, 0.0000MSYS/0.0000,0.0000,0.0000,243.9997,-1.0000000, 0.0000000,0.0000000,0.0000000,1.0000000PAINT/PATHPAINT/TOOL,FULL, 1FEDRAT/MMPM,15000.0000GOTO/-140.0000, 260.0000,159.0250,0.0000000, 0.0000000,1.0000000GOTO/-140.0000,260.0000, 139.0250PAINT/COLOR,3FEDRAT/6000.0000GOTO/128.0000,257.6465,133.4500GOTO/128.0000,233.6465,133.4500GOTO/-120.0000,233.6465,133.4500GOTO/-120.0000,248.6465,133.4500GOTO/120.0000,248.6465,133.4500GOTO/120.0000,243.6465,133.4500GOTO/-128.0000,233.6465,133.4500PAINT/COLOR,7FEDRAT/15000.0000GOTO/-128.0000,243.6465,233.4500PAINT/TOOL,NOMOREEND-OF-PATH…

(This is a fragment of a CL data file created by UniGraphics for Workpiece D - Inner Fısh Plate)

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