Motor pistonu ve piston pimi üretiminde kalite güvence sisteminin kurulmasında kalite tekniklerinin uygulanması
Başlık çevirisi mevcut değil.
- Tez No: 55847
- Danışmanlar: PROF.DR. H. ERMAN TULGAR
- Tez Türü: Yüksek Lisans
- Konular: Metalurji Mühendisliği, Metallurgical Engineering
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1996
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 207
Özet
ÖZET Kalite Güvencesi, günümüzde mühendislik* ve işletme disiplinlerinde en popüler ve güncel konulardan birisi haline gelmiştir. Kalite, konu ve kavram olarak fabrika içerisindeki tekbir departmanın sorumluluğu olmaktan çıkarak, tepe yönetimden, çalışanlara herkesin sorumluluğunda olan bir konudur. Kalite yalnızca üretim sektöründe değil, hizmet sektöründe de benimsenmesi için gerekli olan kavramdır. Bu yüksek lisans çalışması giriş bölümü dışında altı bölümden oluşmuştur. İkinci bölümde kalite, kalite güvencesi, toplam kalite yönetimi, üretim kontrolü, KAIZEN gibi genel kavramlara değinilmiş, üçüncü bölümde otomotiv ve yan sanayi kuruluşları, piston ve pim fabrikasının varlık sebepleri gibi konular araştırılmıştır. Daha sonraki bölümde ise otomotiv sanayinde kullanılan temel ve tamamlayıcı prosesler, otomotiv sanayinde kullanılan malzemeler incelenmiş, motor pistonu ve piston pimi ürün olarak tanıtılmış ve üretim süreçleri, bakım şemaları gibi açıklayıcı bilgilere yer verilmiştir. Tezin uygulama ile ilgili bölümleri son üç bölümde yer almaktadır. 5. Bölümde proses parametreleri, piston ve pim hataları, ıskarta nedenleri ve hata kaynakları, 6. bölümde SPC uygulamaları, temel istatistiksel teknikler, kalitenin 7 temel aracı üzerinde bilgiler verilmiş ve fabrika verilerine dayalı istatistiki ve matematiksel uygulamaların son bölümde ise işletmedeki girdi, ara ve son kontrol faaliyetleri yapılmış, analizler, deneyler, proses kontrol ilişkileri, operasyon ve ara kontrol planlan, formlar, son kontrol sonrası ambalajlama, paketleme ve piyasaya arz gibi işlemler hakkında bilgi verilmiştir. XV
Özet (Çeviri)
THE APPLICATION FOR SETTING UP A QUALITY ASSURANCE SYSTEM IN ENGINE PISTON AND PISTON PIN PRODUCTION WORKING AS A SUBCONDUCTOR SUMMARY Nowadays quality assurance is one of the most important concepts, especially in the industrial life all over the world. Each industrialfirm has lots of goals. Each firm wants to sell mor.e products and earn more money. When it manufactures any product, it spends ajlot of money. Thas improving product quality is very important because with a higher quality a manufacturer firm can reduce all types of cost, necessary for a firm. Costs are affected by quality in a regetory way, but at present with a well-done, well-organized and well planned quality assuarance and quality control system, all kinds of costs can be reduced. Since the beginning of 1980's, the market economy has been effective all over the word. Globallization has become popular: Banking.; Foreign trading, communication systems and technology have became more and more effective. In the world economy demand used to be more than supply, but now supply is more than demand all over world. If consumers' demand is more than supply, consumers desir.es are not very important. Manufacturers produce products and sell them to consumers. Because of the quality control of products, the prices increase, therefore consumers for these products have to spend more money. In the world economy in which supply is more than demand, quality of product becomes more significant. Consumers can select products which are alternative to one another. Consequently producers have to produce their products of a high quality. Because they shoose and purchase the product that they admine. Globallization all over the world affected Turkey just like all the other countries in the world. Turkey has got good commercial relations with European countries especially with the ones, members of European Community such as Germay, France, Italy. Lots of Turkish industrial firms andindusrial groups export their products to the European Community Countries. These Turkish firms which export their products have to b ring an ISO 9000 Quality Assuarance Certification owing to go on with their exporting and thier commercial life, because for this type of firms, it is difficult to go on with their commercial life without exporting to especially European Communiy countries, because European Community Countries have the grestest market for exporting the industrial products. ISO 9000 Standarts are interrational standarts including ISO 9001 to ISO 9004. ISO 9000 Standarts are series. ISO 9000 is called BS 5750 in the United Kingdom, TS-ISO 9000 in Turkey. To be able to achieve the ISO 9000 Quality Assuarance System is a good goint for a factory. This is the result of globallization, the result of Market Economy. Exporting and importing facilities between the xviEuropean Community Countries and other countries will get easier with the ISO 9000 certification. The competition among, the firms producing the some or alternative products has been increasing since the 1980's. So asto compete to achieve ISO 9000 Quality Assurance System and to give the Quality Assuarance Certification are necessary, but these are not enaugh. The most important point is to be able to apply the Total Quality Management (TQM). Total Quality Management is not an aim. Total Quality Management always starts with human quality. Human Quality can be improved by education. Total Qualiyt Management has five important points. These are; 1- Leadership of top-level management 2- Focusing the customers 3- Workers' Education 4- All types of group work 5- Adopting the KAIZEN period. Total Quality Management is not an aim. It is the way to manufacture well quality products with a low price and a higher quality, it is also the way for more succesful management. In the firm taking Total Quality Management people are very important and they ought to be motivated, so their education in a firm is a very significant point. Workers' education in a firm should be planned by the top management of the firm. Human quality should be improved with education. For instance in Japan in mary indusrial firms, workers are -educated five-hundred times in a decade. Top-level management should achieve the quality system.“Quality is a management problem”was said by Dr. Juran, a famous American Quality Control expert. Not only the department of quality assurance and quality contral but also all the people who work in the same firm are responsible for the development of quality. All people should participatein, the quality development facilities. Firm Quality is very important and firm should have a goad image for quality. For Total Quality Management leadership involves defining the needs for change, frameworks for thinking about strategy, structures and people. Japanese businessmen, engineers and workers are the best appliers of quality control and quality assuarance. They have achieved this by their quality and managerial philosophy namely KAIZEN. All types of development can be achieved slowly and with smaller steps with KAIZEN, but all developments are made effectively. Group facilities are very important for quality assuarance. There are different kinds of group work. The most popular one quality control circles. Quality Control Cincles were developed by Dr. Kauru Ishikawa, the Japanese quality control and quality assuarance expert. First it was applied in the Japanese indusrial firms. After that it became very popular in Europe and the USA. Quality is not only necassay in industrial firms. Quality is necessary and have to be applied by all types of firms it is important in hotels, hospitals, banks etc. xviiAutomative Sector is one of the main sectors in each national economy all over the world. Lots of products which are used in automotive factories are manufactured by automative subconductors. Subconductors manufacture some products and after manufacturing, they sell their products to automative factories. Automative factories are customers for their subconductors. Automative factories and their subconductors are definitely affected by competition. For the competition to go on all automative factories and their subconductors have to establisin their quality assuarance systems. Lots of firms and subconductors in the automative sector in Turkey have been able to achieve this. The factory which manufactures engine pistons and piston pings is a kind of subconductor and it works for automative factory. Piston and piston pin factories which have been established in Turkey, work for domestic and foreign markets. This it has to solve its quality assuarance certification probien and ail problems about quality. ISO 9002 standart will be useful for it. ISO 9002 is about production and factory. A piston and a pin are parts of an engine. A piston is one of the main parts, a piston moves into the iron cylinder for working for turning gas into the energy. Piston pings join the connection rool and pistons in the engine. Pistons' production is rather complex. Before the production, the design of the piston is very important since there are a lot of types of pistons and different types can be ordered by the automobile manufacturing firms. 'o Engine pistons are made of aluminium materials. Aluminium copper or alumunium-silisium allays are used for producing pistons. In general alumunium- copper allays are preferned in the United States market, but aluminium-silisium alleys are prefered in the European market. The factory which I have studied for this thesis uses aluminium-silisium al&ys for producing engine pistons. This factory was, set up in İzmit, an important industrial city, in İzmit was been working for the Turkish and European automotive markets and this factory has been working for the quality assuarance certification. In aluminium-silisium allays, silisium is the mainelement. The other important alloy elements are magnesium, iron, and copper. For manufacturing engine pistons with aluminium-silisium allays, two kinds of allays can be used. These are called special alloys and standart allays standart allays can also be class fied as hipaeutectic and eutectic allays. Piston pins are made of carburization steel. 15Cr3, 16MnCrl5, 18CrNi8 are important pins materials 16MnCr5 is the most prefered one. Designing is a very important step for engine piston. You cannot produce good-quality products (piston) with out goad designing. For pistons' production the basic process is casting. For casting metal cores and permenant matals are preferred. Permenant molds are useful for engine pistons. Permenant molds and metal cores are made of special steel. Both of them consist of four or five parts. Before assembling xvuithese parts of mold and core should be machined. After assembling they are machined again, in three or four steps. Preparing allays' is also important. The raw materials of pistons are; 1- Primer rawmaterials 2- Scraps (piston) 3- Working scraps from the machining process. The third type of rawmaterial has to be cleaned before meiting. Rawmaterials are melted in induction furnaces. Chemical rates should be tested. Temperature is the second important point. After melting, the operators should wait. Themelting material should be put into the furnaces used for waiting. For good production some process ought to be applied like the refining of silisium, modification, cleaning processes and removing the gas especially the hydrogen and inclusions. After casting process, heat treating is applied to engine pistons. Aging is the most useful process for the modification for of engine pistons. After precasting, casting and postcasting processes, machining the second important and main process series By using and applying machining processes, very important parts of a piston are machined. In the machining process, there are lots of process steps. After machining, other important step is plating processes. Four kinds of plating processes are applied to. pistons. These are 1- Graphit plating 2- Phasphar plating 3- Hand ano dizing 4- Tin plating Hard anodizing is a useful and popular plating process for plating engine pistons. Plating processes are used for developping some piston properties such as cornosion properties, some mechanical properties such as the handness of the piston surface, wearing. Although piston pings are manufactured in a piston factory, they are made of different types of material and manufactured by definetely different processes. The most important pins production process is the heat treatment. As a heat treament process, carburization (gaz carburizaiton) is used. It is the most important step for manufacturing piston pins generally all over the world engine pistons and piston pin are manufactured together (in the same factory, but in different parts). Before and after heat trastment machining processes are used. After heat tresting process, the hardness and. strenght will incresse. For manufacturing pistons there are two sorts of faults or scr aps. These are called. 1- Casting scraps 2- Machining scraps xixTotal scrap rates depending upon machining processes are usually more than casting scraps After having calculated, the total scrap rates for each period for example monthly scrap rates chould be calculated for pistons. There are also two kinds of scrap for piston pins. These are called as; 1- Material scraps 2- Machining scraps The total scrap rates for piston are also calculated, after calculated the other ones. To be able to manufacture better quality products there must be some faults, and you have to notice these faults. This the.prosessand system parameters must be known for each process. For matance to be able to solve the porozity and cality problems as a casting fault, you should learn the details in casting of aluminium- silisium casting process. After that you one able to prevent or decrease the scrap rate depending on this land of problem. You can solve or prevent the problems depending on processes in a deterministic way. To be able to observe the process, SPC (Statistical Process Control) is a useful way. Engine pistons are complex products. They are good products or the unfinished products should be measuned. Fifthy a, hundned or a hundned and twenty five samples should be taken from the group of products. There are some statistical techniques or calculations for controling processes. We can classify these. These are; 1- Basic Statistical Methods (Aritmetical Mean, mod, median, standart deviation, variance, range) 2- Collecting datas from s amples having been taken 3- Histognams 4- Bar and pie graphics 5- Time-seri plots 6- Scrap Analysis 7- Correlation Analysis and Scotter Diagrams 8- Pareto Analysis and Pareto Diagrams 9- Control Tables 10- Forming groups techniques 1 1- Cause and Effect Techniques and Diagrams 12- Machine Capability Analysis 13- Process Control Charts (Skewhart Charts) 14- P Charts 1 5- Quality Cost Analysis XX.There are lats of examples and applications of some of these techniques. In the factory which I have stadied, there is no, statistical process control in the pin factory, in spite of this, I tried to apply some tedriques for piston pins. As I mentianed before, some of these. methods such as Pareto Analysis, histograms, cause and effect diagrams, machine capability analysis were applied both for engine pistons and piston pins, whrist time-series plots, scrap analysis, control charts were only applied for engine pistons. Time-series plots is a useful method for scrap analysis. By means of statistical process control (SPC), we can solve many problems about pistons. Pistons are very complex shaped products. Most scrap problems are caused by machining process. These rates are from 1% to 5%. These rates are quite high. We are able to decresse these rates with statistical process control. Pareto Analysis should' be done monthly and annually. Processes should be controlled by the process control charts. Machine apability should be calculated. For Pareto Diagrams all kinds of scraps should be classified and the four or five highest scrap-types ought to be examined. The causes of the type of scrap should be determined. These causes should be categorized such as man, machine, environment, material and methods. After that the cause and effect (Ishikawa) diagrams should be drawn. For this study two cause and effect (CE) diagrams were developed and drawn. The first diagram is about pins, the other one is about engine pistons I have studied for piston and pin foults with cause and effect diagrams. After the pareto analysis the most important problem of piston pins is grinding problems. Grinding faults include, the first, second.and thind important groups of faults. First of all the main groups were determined. These groups are also called 4M. (Machine, method, material and man), after that the cause and effect diagrams were drawn. This sort of cause and affect diaram is a general cause and affect diagram. For engine pistons, porozity fault was analized. The causes of all casting processes were determined. After having been determined, the cause and effect diagram about prozity was drawn. This type of cause and effect diagram which was drawn for the prozity fault for engine pistons is called period cause effect diagram. I prefered this type of cause and effect diagram because prozity for castings depends upon different processes. The last chapter, (7th Chapter) is about controls of engine pistons and piston pins. To control engine pistons and piston pins is very important for manufacturing good-quality products. It is also very important all types of manufacturing system. Control facilities can be classified in three main parts. These are 1- Input Control 2- Intermadiate Controls 3- Output Control For Dr. Kauru Ishikawa, famous Japanese Quality Expert, intermadiate control is of great importance. Next process is customer. XXIIn both piston production and piston piston pins production for input control, all kinds of input materials ought to be controlled, in not good or out of standarts, these should be sent back. There are two main types of input controls. These are called; 1- Spectrometry Analysis 2- Metalographic Analysis Spectrometric Analysis is used for chemical analysis. It is used for both piston and pin's chemical analysis. Other type of analysis is metalographic analysis. Metalographic tests are used for analysing piston and piston pins microstructures. These two testing methods can be also used for intermadiate testing. Especially after the casting, madification and heat treatment processes. For applying these kinds of testing methods, samples from engine pistons and piston pins should be taken. After all processing steps intermadiate controls should be done, effectively. These controls are so important so as to be able to produce good qualiyt products. For intermadiate controls, physical measurement, chemical (spectrometric) analysis, metalographic analysis, some mechanical tests should be done. Physical measurements are particularly important after the all steps of machining processes. During the machining processes, the liquid that is used for the machining processes should be controlled. Its concentration and temperature should be measured. Some forms should be prepared for intermadiate control. For example machining scrap tables, consantration and temperature observing form, operation charts, operation planning form, process control forms, 'should be prepared, after all controling facilities, the results of testing should be wr itten on the forms. For plating processes there are some important intermadiate controls. These are chemical controls, PH Test, surface testing control etc. For piston pins many physical measurement controls should be done after the machining processes, the hardness tests should be done after the heattreatment process. The last step is output control. Output control is done for both pistons and pins. All pistons and piston pins are controlled, after having been manufactured. After controlling pistons and pins are supplied for the automotive facturies. xxu
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