Publication: Sıcak dövme işleminde karşılaşılan hatalar, önlenmesi ve maliyete etkisi
Abstract
SICAK DÖVME İŞLEMİNDE KARŞILAŞILAN HATALAR, ÖNLENMESİ VE MALİYETE ETKİSİ Günümüzde hemen her ölçekteki firmalar daha ekonomik, hatasız ve kaliteli bir şekilde üretilmiş parçaları tercih etmektedir. Sıcak Dövme İşleminde hatasız mamül üretebilmek için oluşabilecek hataları önleyici tedbirler almak gerekir (Kalıpların yeterli sıcaklıkta olması, Montaj yapılmadan önce kalıplardan alçı alınması, fırın sıcaklıklarının kontrol edilmesi, numune malzeme döverek kalite kontrolden uygunluk raporu alınması vs. ). Bunların yanında, imalatı gerçekleştiren operatör faktörü çok önemlidir. Operatör, montajı hatasız bir şekilde yapmalı ve dövdüğü malzemeyi gözle sürekli kontrol etmelidir. Uygun bir şekilde talaş kullanılmalı ve yağlama yapmalıdır. Endüstride Sıcak Dövme işlemi ile üretilen parçalar yaygın bir şekilde kullanılmaktadır. Buna rağmen endüstride bu konu ile ilgili yazılı doküman çok az sayıdadır. Bu çalışmada Dövme Yöntemleri, Sıcak Dövmede karşılaşılan hatalar, çözüm önerileri ve maliyete etkisinin incelenmesi amaçlanmıştır. Bu çalışmada, Sıcak Dövme Hataları tespit edilip, çözüm önerileri sunulmuş ve hataların maliyete etkisi incelenmiştir. Oluşabilecek hatalar malzemeye, tezgaha, fırınlara vs. göre değişiklik arz edebilir. Konunun iyi bir şekilde aktarılması için Parsan A.Ş. Dövme Atelyesinde üretilen malzemeler detaylı bir şekilde incelenmiş, sorunların çözümleri gerçekleştirilerek, hatalardan kaynaklanan maliyetler ortaya konmuştur. Sıcak Dövme, Dövme Yöntemleri ve Makineleri, Dövme Fırınları, Dövme Hataları, Maliyet analizi
DEFECTS AT HOT FORGING PROCESS, PREVENTION OF THESE DEFECTS AND THEIR EFFECT ON THE COST Today nearly all medium size companies prefer to use more qualified components with fewer defects which are also produced more economically. In order to manufacture a perfect product through the Hot Forging Process it is essential to take preventive measures that will eliminate possible mistakes (for example, moulds should have sufficient heat; before assembling plaster models must be taken from the moulds; the temperature of the furnace must be checked, a conformity report should be obtained from the quality assurance by forging a sample material). Moreover, the operator who performs the manufacture plays a significant role in the production process. He must conduct assembling properly and always check the material he is forging. The usage of the sawdust and lubrication require to be performed appropriately. The products manufactured through the Hot Forging Process are widely used in the industry. However, written document on this subject is very limited. In this thesis it is aimed to study on the Forging Methods, Defects experienced at Hot Forging Process, solution offers and their effects on the cost. In this study defects of the Hot Forging were found, solution offers were introduced and their effects on the cost were discussed. Possible defects of the process may vary according to a range of reasons including the materials, forging machine and the furnace etc. The products which have been manufactured at Parsan A.Ş. Forging Plant were examined carefully and the costs of the defects were figured out in order to clarify the subject. Key words : Hot Forging, Forging Techniques and Forging Machines, Forging Furnaces, Forging Defects, Cost Analysis
DEFECTS AT HOT FORGING PROCESS, PREVENTION OF THESE DEFECTS AND THEIR EFFECT ON THE COST Today nearly all medium size companies prefer to use more qualified components with fewer defects which are also produced more economically. In order to manufacture a perfect product through the Hot Forging Process it is essential to take preventive measures that will eliminate possible mistakes (for example, moulds should have sufficient heat; before assembling plaster models must be taken from the moulds; the temperature of the furnace must be checked, a conformity report should be obtained from the quality assurance by forging a sample material). Moreover, the operator who performs the manufacture plays a significant role in the production process. He must conduct assembling properly and always check the material he is forging. The usage of the sawdust and lubrication require to be performed appropriately. The products manufactured through the Hot Forging Process are widely used in the industry. However, written document on this subject is very limited. In this thesis it is aimed to study on the Forging Methods, Defects experienced at Hot Forging Process, solution offers and their effects on the cost. In this study defects of the Hot Forging were found, solution offers were introduced and their effects on the cost were discussed. Possible defects of the process may vary according to a range of reasons including the materials, forging machine and the furnace etc. The products which have been manufactured at Parsan A.Ş. Forging Plant were examined carefully and the costs of the defects were figured out in order to clarify the subject. Key words : Hot Forging, Forging Techniques and Forging Machines, Forging Furnaces, Forging Defects, Cost Analysis