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Sıcak dövme endüstrisi sektör araştırması

Hot forging industry

  1. Tez No: 39686
  2. Yazar: NAZAN ALAYALI
  3. Danışmanlar: PROF.DR. AHMET ARAN
  4. Tez Türü: Yüksek Lisans
  5. Konular: Makine Mühendisliği, Mechanical Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1994
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Belirtilmemiş.
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 81

Özet

ÖZET Genel anlamda Dövme, metalin, çekiç darbeleri ile ya da pres basıncı altında sıcak şekillendirilmesine denir, Dövme işlemi ile birçok makina parçası, değişik şekil ve boylarda elde edilebilir. Burada yapılan çalışmanın birinci aşamasında Sıcak Dövmede uygulanan yöntemler ve kullanılan makinalar geniş çaplı olarak incelenmiştir. Çalışmanın ikinci aşaması ise Sıcak Dövme Sektörü' nde yapılan bir anket araştırmasıdır. Yapılan anketin amacı son yıllarda Sıcak Dövme konusunda hiçbir araştırma yapılmadığından, günümüzdeki son durumu ortaya koymaktır. Anket için başvurulan firmaların büyük çoğunluğu ya nıt vermediği halde, çalışmaya katılan 8 firmanın sonuçla rı ve mevcut kaynaklardaki veriler birleştirilerek genel durum değerlendirmesi yapılmaya çalışılmıştır. Çalışmaya katılan firma sayısı çok az olduğu için ye tersiz kalan sonuçlar ile Sıcak Dövme Sektörü 'nün bugünkü durumunu ve son yıllarda ne gibi değişmeler olduğunu çalış manın sonucunda görebilirsiniz. v

Özet (Çeviri)

summary HOT FORGING INDUSTRY Forging is the hot working of metals performed by- means of hammer blows or under the pressure of a press Various kinds of machine parts, of different shapes and sizes, are made by forging operations. Depending on the methods of the production of for- gins, forging processes are classified as Hammer and Die Forging. In Hammer Forging, shape of the metal is changed by pressing it between the dies of a hammer or a press. In doing this, the flow of the metal (i.e. the changing of its dimensions and shape) is controlled with the aid of various blacksmith's tools. In Drop Forging or Die Forging, the flow of metal is limited by the surfaces of the recesses in the dies, in which the metal takes its predetermined shape and dimen sions. Every part manufactured by the drop forging process requires a separate die or set of dies. Forged parts, whether they are to be machined or not, are called Forgings. Forgings which have to undergo subsequent machining are called Blanks. Those which do not require any further machining are known as Finished Forgings. Forging processes are. extremely important in the machine building industry. No machine, whether simple or complicated, can be built without the use of forgings. Hammer Forging and Die Forging is particularly widespread in the tractor, automobile, agricultural machinery, ship building, locomotive building and other industries. For instance, in the railway-car building industry up to 70% of all the parts which go to make a car are forgings. Not only parts of machines, but also many tools manufac tured by forging. vxThe widespread use of forging is explained by the fact that forging improves the quality of steel, which becomes stronger after forging. For this reason, machine parts which are subjected to heavy duty are generally made of forgings. Moreover, the time required for the manufac ture of a part or a tool is very often reduced by forging, much less steel is consumed in its production and con sequently the cost of any given part is reduced. The enormous importance of forging operations is shown by the fact that, nearly, every machine shop has a forge division, andevery machine building plant a forge and die forging shop. One and the same component can be forged by different methods and on dif f erentforging machines. However it is always necessary to select the most suitable method for making any given forging, which will: a- Ensure a high quality forging; b- Ensure high productivity; c- Entail the minimum consumption of physical energy on the part of the workers; d- Entail the minimum comsumption of metal; e- Ensure complete safety during forging. The process of making a part by forging consists of several separate operations, the chief of which are: 1- Selecting and preparing the stock for forging; 2- Heating the metal for forging; 3- Forging the stock- to the requisite shape and dimen sions. The process of making any piece of work by the hammer forging method entails many different forging operations; cutting, upsetting, bending, drawing, piercing, punching, drifting, twisting and surface finishing. The production of any kind of forging necessitates the employment of some or all of these operations in different sequences. Some times one, two, or three operations (steps) may have to be repeated several times. VllEvery blacksmith should always try to make his for- gings in the least possible number of operations. This will reduce the time needed for making the forging, reduce the number of heatings and, consequently, increase his productivity. Before commencing to make any forging, the blacksmith should know exactly which operations are to be employed, and in what sequence. The tools and devices which he selects will depend on tne method of forging. The blacksmith generally works together with one or more strikers and to ensure perfect co-ordination between him and his strikers, he must explain the sequence of each operation and tell them, beforehand, which tools they will have to use. The striker, under the blacksmiths supervision, has to put each tool in its working place in the order of the operations to be performed; this prevents any delays entailed in looking for the required tools during the work. The basic document for making any hammer forging is what is called the technological process chart, which sets out the sequence of each forging operation. When "we look the literature, we see that in recent years, there has been made no search about Hot Forging Industry. For that reason, we started an inguiry work about this subject. During this inguiry, we applied 26 firms working on Hot Forging but unfortunately only 8 of them gave answer to the inguiry given as annexa. The list of the firms, taking part in this inguiry, is given in the table below (they are written the alphabetic order). Table: The Firms Taking Part In The Inguiry ALTAŞ El Aletleri Sanayi ve Ticaret A.Ş. ARMAS AN A.Ş. ÇELİK SANAYİ A.Ş. DÖV-HAS Sıcak Dövme Sanayi ve Ticaret Ltd.Şti. İZELTAŞ El 'Aletleri Ticaret ve Sanayi A.Ş. KANCA El 'Aletleri ve Çelik Sanayi A.Ş. LAS- ZIRH TURAN Makina ve Yedek Parça Sanayi A.Ş. Though it is known that a healthy result can not be received, a situation comparison is done. During this work, Forging Industry Search by Mustafa GEVREK, Ahmet ARAN, Sadettin OZAN, 1978 and Turkish Steel Forging vxnIndustry by Basri KANCA, 1993 are the main documents app lied. By the help of these documentations, the data is connected, a general result is obtained. As 26 firms are applied, but only 8 of them gave answer to the inquiry, the conclusion is just a general view of Hot Forging Industry, and the point this industry reached in the last 16 years. General Conclusions: Most of the personnel, in forging firms, do exist in the forging plant. High educated Technical Personnel generally dense in Management while Qualified Workers and Normal Workers employ in the Forging Plant. There seems to be some increase in Forging Capacity. Another data supporting this conclusionis the increase in the working hours, almost as 3 times. Nowadays the capacity use is just 70% and we reach such capacity. This shows that at 100% capacity use, capacity value will rise quite a lot. The factors, preventing the use of capacity 1978, such as Raw Material, Worker Problem and Energy, are mostly put aside, and Marketing is left as the only problem. If suitable Marketing was found, by using 100% capacity, large amounts of productions would be reached. While talking about the answer of the inguiry, just talking about Forging Machines is enough to show the general attitude of forging. Since 1978, the machines, to be taken in to work, are generally with high capacity and convenient to the high tecnology of our day. They are mostly taken into work between the years 1978-1985. As it can be understood from these, after 1980 's, the economical ease has affected Forging Industry a quite deal. So by the help of the modern machines, using less labour and in a shorter time, it has become possible to reach large capacities. According to the answers of the 8 firms taking part in the inquiry, the use of import material is lessened. But as it is pointed out in the article by Basri KANCA, improved export conditions, the economical ease after 1980s and the annihilation of foreign currency problem, it is expected to be some rise in the use of import mate rial. We can arrange the materials used in forging into three groups: xx1- Carbon Steel 2- Alloyed Steel 3- Heat Resistant High Alloyed Steel The Automobile Industry takes the biggest part of the sales. Though in less amounts, Special Tools such as lifting tools and hand tools, Agriculture Vehicles, Railways, Mining and Shipping are the parts taking part in this market. In recent years. Defence and Petrolium also begin to take part in the market and every passing day they increase their share. Sales to the Foreign Countries show an increasing trend both in the number of the countries and in the number of products. The products such as machine parts, hand-tools, building materials, agriculture vehicles, forging models, etc. are sold increasing amounts to Germany, S.Arabia, England, Greece, Portugal, Italy, etc. Talking about Quality Control, all of the firms taking part in the inquiry either do started the works for ISO-9000 or has already started ISO-9000. Besides, all the controls are done by following a certain plan and by taking examples according to a plan. 6 of the firms taking part in the inquiry has started New Project sand Investments (2 of the firms gave no answer to this question). Increase in the capacity is the main aim of this work, but not the only Modernization in tech- nolgy, renewing of machines, ordering of working and by the help of these, achieving good relations both with the customer and the raw material, increase in the quality assuring the health of workers and surroundings are the other aims.

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