ISTANBUL AYDIN UNIVERSITY
PROJECT
BEVELING MACHINE
Fatma Nida OKUTAN B1905.030029
Pelinsu ÇAM B1905.030047
Berna ALTAŞ B1905.030037
Bertuğ DOĞAN B1905.030017
DEPARTMENT OF INDUSTRIAL ENGINEERING
COURSE: Manufacturing process
ADVISOR: Raheleh MIRZAI
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ABSTRACT
In the beveling machine process, we first start with the project design. At this stage,
the technical drawings of the project are drawn, and the sheet metals needed are ordered.
The first step after the sheet metals arrive is sandblasting to prevent corrosion. It is
preformed to give the general shape after sandblasting. Sheet metals that have been shaped
are primed to prevent re-corrosion. Sheet metals from preforming are marked to avoid
confusion. precision measurement stage is reached. In the machining stage, sheet metals
pass through various processes to reach precise measurements. After reaching the precise
dimensions, the basic parts are joined by welding. Finally, all welded or non-welded metals
are bolted together so that the machine can be whole. After the electrical wiring and
hydraulics are assembled, they are ready to work.
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TABLE OF CONTENTS
ABSTRACT…………………………………………………………………………………………………………………………….3
TABLE OF CONTENTS…….……………………………………………………………………………………….…………….4
INTRODUCTION…………………………………………………………………………………………………………………….5
1. PROJECT DESIGN.………………………………………………………………………………………………………………6
2. SAND BLASTING………………………………………………………………………………………………………….…….7
3. PRE-FORMING…………………………………………………………………………………………….…………….………8
3.1 Oxygen Cutting……………………………………………………………………………………….……………………9
3.2 Plasma Cutting……………………………………………………………………………………...………………………10
3.3 Guillotine Shear ………………………………………………………………………………….…………………….11
3.4 Press Brake……………………………………………………………………………………………………….….……12
3.5 Sawing Machine…………………………………………………………………………………………………………13
4. PRIMER COATING……………………………………………………………………………………………………………14
5. MARKING………………………………………………………………………………………………………………………..15
6. MACHINING…………………………………………………………………………………………………….………………16
6.1 Milling…………………………………………………………………………………………………..……………………17
6.2 Lathe………………………………………………………………………………………………..……………………..…18
6.3 CNC (Computer Numerical Control) …………………………………………………………………………..19
7. WELDING…………………………………………………………………………………………………………………………22
8. ASSEMBLY…………………………………………………………………………………………………..……………..……24
9. CONCLUSION…………………………………………………………………………………………………………….…… 28
10. REFERENCES……………………………………………………………………………………………………………….…29
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INTRODUCTION
The machine we examined is the welding beveling machine. Weld beveling machine
provides easier joining of pipes. For example, we can weld 5 meters of pipes to each other to
obtain 5 km of pipes. Welding cannot be done without opening the mouth of the pipes with
the welding machine. The machine that facilitates this welding is the beveling machine.
Today, there are 2 factories in Turkey that make the beveling machine. In this project, we
went to Tümay Makina and examined all the stages of the beveling machine made for the
Tosçelik factory.
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1. Project Design
The first thing to do when starting the project production is the technical drawing
after the agreements and requests. Technical drawing determines the amount, type, and
size of the required material. Accordingly, purchases begin. The tone and type of sheet metal
are determined according to the desired beveling machine. Manufacturing begins with the
arrival of the ordered sheet metal. Most of the processes made, pre-forming, cutting,
machining, and assembling are done according to these technical drawings. Therefore, the
most important issue is the project design and technical drawing.
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2. Sand blasting
The first process of incoming sheet metal is sand blasting. Sand blasting is to destroy
the oil, dirt, rust, and corrosion that has formed on the sheet metal over time. Sand blasting
is the cleaning of unwanted materials by combining the fine sand particles with high
pressure air and hitting the sheet metal surface. The sand blasting machine is located
directly at the beginning of the factory and the metals that are not sand blasted do not
enter. There are elongated structures in the form of small pipes in front of and behind the
sand blasting machine. These structures transmit the sheet metal to the sand blasting
machine and enable sheet metal to be removed from there. At the end of sand blasting, the
rust is removed and cleaned, that is, a smoother sheet metal is obtained.
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3. Pre-Forming
The pre-forming stage is the most important of the stages and is the heart of the
manufacturing. It includes cutting and forming. The cuts may differ depending on the size of
the metal. The cuts used for the beveling machine are oxygen cutting, plasma cutting and
upcut shear. The cuts are made according to the technical drawings made by the project
design. The dimensions in these technical drawings are entered into the cutting machine
software exactly and the machine cuts to this exact size. After the cutting process is finished,
some metals are sent to the primer coating. Primer coated ones are ready for marking.
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3.1 Oxygen cutting
Oxygen cutting used in almost every field. It is widely used because it cuts hard and
thick metals most easily. It is used for metal cutting larger than 25mm. This method is
simply cutting steel by heating. In other words, it is the process of cutting the material to be
cut using flammable and combustible gases. Oxygen is used as the combustible gas and
acetylene and propane are used as the combustible gas. The cutting torches used for this
cut have two hose inlets. Oxygen is sent from one and gas is sent from the other. The cutting
process is carried out with the pressure action of oxygen and gas. It can be adjusted with the
buttons when it is desired to increase or decrease the settings.
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3.2 Plasma cutting
It is the realization of cutting in conductive materials by means of direct current
power source ionizing compressed air and turning it into plasma. Power supply, constant
compressed air, appropriate type of torch is required for cutting to take place. Plasma
cutting can be applied to all conductive metals. It is used for cutting less than 25 mm. It
costs less than oxygen cutting. Heat is used in plasma cutting. In thick metals, this heat will
cause expansion and the metal is deformed. To avoid expansion, plasma cutting is not used
on thick metals.
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3.3 Guillotine Shear
The process made by breaking the metal that is difficult to cut is called guillotine
shear. The cutting process in guillotine shear has the same principle as the scissors we use in
daily life. How it is going to be cut are added to the computer counting management and the
cutting process is performed. Guillotine shears have double blades. These knives are divided
into two as fixed and movable. It is used in very thin cuts. (1mm-10mm..). Workman put the
metal into the machine and machine cut the metal like scissors.
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3.4 Press Brake
The press brake bends very thin sheets. It is a cold bending. Sheet metal is shaped by
pressing between two dies. a press brake bends the sheet metal by lowering a punch onto
the sheet metal placed on top of a die. It can also bend large metals.
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3.5 Sawing Machine
In pre-forming, round or bar cut can be cut with a saw. Saws often make rough cuts
for the beveling machine. The machine works with liquid as it is easier to cut the surface
lubricated with liquid.
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4. Primer Coating (Undercoating)
Primer coating, the other name of undercoating, is done by spraying the special paint
on the sheet metal from a distance with high pressure air. If the metal is small enough, it is
directly primer coated. If it is large, the cutting stage comes first and is primer coated after
cutting. The most important reason for primer coating is to prevent re-rusting of the sheet
metal, which we remove the rust and dirt with sand blasting. Primer coating is to ensure
analyzed easier and assembly homogenously. if we skip this stage, the metal become
roughness and rusty.
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5. Marking
Marking is a small but functional stage, parts that are sand blasted and then cut
and primer coated are marked to avoid confusion. Where it will go, what part it is, and the
technical drawing number are written on it. The marking process is done according to the
technical drawing, so it is easy to see which part will be assembled with which part. A lot of
machines are made at the same time in a factory, thanks to this stage, these parts are
prevented from getting mixed up.
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6. Machining
The machining stage is the stage where parts are precision machined. The sheet
metal that has come out of the cutting stage has no millimetric precision. Millimetric
precision is required from some critical parts. Precise dimensions are reached by processing
in machines such as milling, lathe, borwerk and CNC. These precise measurements are
based on the technical drawing. The machining stage not only processes the precision
dimensions, but also cuts the wheel cavities and assembly slots with the help of the milling.
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6.1 Milling
Milling is the shaping of the sheet metal, which is stationary with the cutting tip
rotating around its own axis, by removing metallic chips. Milling machines can be used for
machining flat and angled surfaces, grooving, making straight and circular partitions. The
milling sheet allows the metal to reach precise dimensions beside enables the opening of
gaps such as wheel gap. Connection points, bedding, bushing points, perpendicular and
parallelism sensitive areas on the machine are made by milling. According to metallic pieces
and precision dimensions there are small or large milling machines. But some metallic pieces
are too large milling machine so in this situation, borwerk machine does the job. Borwerk
machine has the same working principle with milling machine but larger than milling
machine and it works with larger metallic pieces.
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6.2 Lathe
The working principle of the lathe is that the sheet metal rotates, and the cutting
tip remains fixed, removing the chips and shaping it. Precise measurements are reached. It is
generally used for precision machining of cylindrical shaped materials. The advantage is that
it allows to gather cylindrical sections on a part around the same axis. We use it to make
shaft, wheel, bush, cap, hive, and bushing points. As in milling, there are large and small
lathes for large and small parts. The reason why the cylindrical form is generally used in the
lathe is that the cutting tip rotates, and the metal remains stationary.
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6.3 CNC (Computer Numerical Control)
CNC device can do all the precision shaping of turning and milling in an unmanned
way. Technical drawings are coded into the computer, and it can shape and cut precisely
without human touch. Automatically processes with a special computer operating system.
As it is understood from the expansion, it works with the numerical control made by the
computer. The most important requirement for its work is technical drawing codes. The
working principle of CNC machines is machine tools where the material or part is clamped
and rotated by the main spindle, and the cutting tool working on the material is mounted
and moved. Cutting oil is used in CNC. The cutting oil prevents heating due to friction and
provides easy cutting.
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Mounting holes are drilled with drills. Drills are used in some holes that can be drilled
with milling machines because it is more practical, fast, and less costly. As a result, turning,
milling, CNC and drilling operations are carried out with precision and after rough cutting
operations, metal parts are ready for full shape. some of these are called machining in
general. And machining can also be done in some cases and in some metallic parts after pre-
welding.
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7. Welding
Sheet metal, whose welding process is briefly cut, formed, and reached to precise
dimensions with machining, is combine with covered welding. Covered welding is generally
used as a welding method when making a beveling machine. In covered welding electrode or
wire are used. The electrode and wire are melted, acting as glue, and allowing the two parts
to be fused. A high current is created to melt the electrode and wire. The mig mag welding is
a type of the covered welding methods. And we use mig mag welding during the
manufacture of beveling machine. The mig mag welding is quicker than electrode or wire,
but less sturdy. Both methods are used when we manufacture a beveling machine, but the
parts to be joined that need to be more robust are welded with electrodes. Usually, large
sheet metals and sheet metals that cannot be machined in one time are joined by welding.
Welds are made by looking at the technical drawing. The marking stage is important here
because it shows which part belongs to the which technical drawing. After welding, material
and size control is done. Welds and robustness are tested. Those that pass the test are ready
for assembly, but some welded parts return to the machining stage for precision dimensions.
Except for precision dimensions, it goes to machining to drill holes and clean and smooth
surfaces. Most of times, before welding stage, we weld with tag. Tag welding is pre-joining
by centering some parts of the parts to be joined. It provides a front view before welding
and is easier to both weld and cut. After welding, welding wastes are cleaned mechanically
with the help of brushes.
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8. Assembly
Welded or directly shaped sheet metals are connected to each other by bolted
assembly. Bolted assembly is done for disassembly and repair. The biggest advantage of
bolted assembly is that it can be disassembled again. Bolted assembly is the tightening of the
bolt with the help of human and tool by matching the bolt gaps cut by the drill and milling
cutter. The assembly stage ensures that the beveling machine emerges. There are assembly
sequences as sub-assemblies and main assemblies. Intermediate assemblies are usually the
assembly of small parts. the master assembly is the final assembly to build the whole. all of
them are mounted by bolting method. It is cleaned mechanically with a brush. It is cleaned
with solvent-based chemicals and becomes ready for painting. and pre-painting is done after
assembly.
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The whole machine consists of independent sub-assemblies. Production planning and
sequencing are arranged and done according to sub-assembly groups. First, the sub-
assembly parts and auxiliary elements that have been produced are brought together.
Auxiliary elements, bolts, motor, reducer, belt, pulley, bearing, oil, and dust seals are all
brought together. After the sub-assemblies are completed, the machine integrity is ensured
by assembling with the sub-assemblies prepared beforehand. Machine parts such as motor
and reducer are standard. And it is assembled with direct bolted assembly.
After the mechanical assembly is completed, the electrical assembly begins. Electrical
connections are drawn, and electrical panels are installed.
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Clamps that made by plasma cutting helps to keep the pipe stable. Post-installed
pistons help to grip and tighten the pipe. Wheels are assembled in the wheel cavities
opened by milling. The beveling machine opens the weld mouth to the pipe and allows the
pipes to be welded together. This weld beveling process is done with diamond. The diamond
is inserted in the process. After the machine is completed, dyeing is done in the desired
color.
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CONCLUSION
Sheet metals, which were shaped and reached to precise dimensions, were
assembled, and became a whole and conformed to the technical drawing shown at the
beginning. We understood the importance of technical drawing used in many stages. we
observed that the use of more than one method at some stages depends on the size and
type of sheet metal. We have seen that the reason for using bolts in assembly is the
disassembly and reassembly of the parts. We observed that sheet metals of different shapes
are used in machining due to the differences in the working principles of the machines. At
the end of these stages, after the electrical installation and hydraulic installation, our
machine becomes operational.
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REFERENCES
• Tümay Makine Hatay/İskenderun
• https://www.tumaymakine.com
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