Seri Üretim Boru Bağlantı Elemanlarının Döküm İşleminde Optimizasyon
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Dosyalar
Tarih
2017
Dergi Başlığı
Dergi ISSN
Cilt Başlığı
Yayıncı
Gazi Univ
Erişim Hakkı
info:eu-repo/semantics/closedAccess
Özet
Bu çalışmada petrol ve doğalgaz hatlarında yaygın olarak kullanılan ½", ¾", 1", 1½", 2" çaplarındaki boru bağlantı elemanlarının
tasarım ve üretiminde optimizasyonlar gerçekleştirilerek üretim verimliliğinin arttırılması araştırılmıştır. Yapılan çalışmalarda TS
EN 10242 standart ölçülerine göre üretim ve inceleme yapılmıştır. Üretim verimliliğini etkileyen faktörler neden sonuç diyagramı
yardımıyla incelenmiştir. Ürünlerin standartlara göre ortalama %12 daha ağır olduğu tespit edilmiş, modellerin yerleşiminde ise
çeşitli hatalar saptanmıştır. 300×400 mm'lik derece sisteminin boru bağlantı üretimi için uygun olmadığı gözlemlenmiştir. Bunun
yanında yolluk ağırlığının fazla ve yolluk giriş tasarımının hatalı olduğu belirlenmiştir. Bu sorunların çözümü için model üretim
yöntemlerinin oluşturduğu hatalar araştırılmıştır. Bu araştırmalar sonrasında üretimde yeni bir yöntem geliştirilerek optimizasyon
sağlanmıştır. Ayrıca boru bağlantı elemanlarının model üzerindeki yerleşim planının dizilim parametreleri matematiksel
formüllerle ifade edilmiştir. Elde edilen bu formüllere göre boru bağlantı elemanları için en iyi sonucu 420x500' lük derece
sisteminin verdiği saptanmıştır. Kullanılan bu yöntem sonucu firmada seri üretimi gerçekleştirilen ½", ¾", 1", 1½", 2'' çaplarındaki
boru bağlantı elemanları gözden geçirilip bu ürünlerde düzenlenmeye gidilmiştir. Bu sayede üretimin %90'ı optimize edilmiştir.
Toplam yıllık hurda malzeme ağırlığı 246,660 kg'dan 188,496 kg'a düşürülmüştür. Ürünler TSE standart ölçülerine göre
şekillendirilerek hata oranı azaltılmıştır ve malzeme ağırlıklarında %8-20 arasında düşüş sağlanmıştır. Geliştirilen yeni derece
sistemi TÜBİTAK patent desteği almış ve 2013/00806 numaralı “Fittings malzemelerin dökümü için derece modeli'' adıyla
Rusya'da incelenerek patente uygun görülmüştür
In this study, improvement of manufacturing efficiency was investigated by conducing optimizations on the design and production of 1/2 '', 3/4 '', 1 '', 11/2 '', 2 '' fittings which are widely used in the oil and natural gas pipe lines. Manufacturing processes and inspections were carried out according to TS EN 10242 standard dimensions. Factors which affect the production efficiency are analyzed by using cause and effect diagram. As a result of the investigations, it was determined that the products are averagely 12% heavier than standards and some errors were found at the placement of models. It was observed that, 300x400 flask system does not pertain for the for the fittings production. Besides, it was seen that runner weight is too much and runner gate is imperfect. For the solution of these problems, errors which are created by manufacturing methods were studied. After these studies, a new method of production was developed in order to perform an optimization. Also, layout parameters of fittings on the models were expressed with mathematical formulas. With the obtained information, it was detected that the best result was attained from 420x500 flask system. As a result of this method,1/2 '', 3/4 '', 1 '', 11/2 '', 2 '' fittings which are mass produced at the company were reviewed and adjusted. Thus, 90% of the production was optimized. Overall weights of scrap were reduced to 118,496 kg from 246,660 kg. Amount of error is decreased by shaping of products due to TSE standards and weights of products were decreased by 8-20%. New flask system took support of patent form TUBITAK and it was found suitable for patent in Russia with the name of "Flask model of fittings"(Patent nu: 2013/00806).
In this study, improvement of manufacturing efficiency was investigated by conducing optimizations on the design and production of 1/2 '', 3/4 '', 1 '', 11/2 '', 2 '' fittings which are widely used in the oil and natural gas pipe lines. Manufacturing processes and inspections were carried out according to TS EN 10242 standard dimensions. Factors which affect the production efficiency are analyzed by using cause and effect diagram. As a result of the investigations, it was determined that the products are averagely 12% heavier than standards and some errors were found at the placement of models. It was observed that, 300x400 flask system does not pertain for the for the fittings production. Besides, it was seen that runner weight is too much and runner gate is imperfect. For the solution of these problems, errors which are created by manufacturing methods were studied. After these studies, a new method of production was developed in order to perform an optimization. Also, layout parameters of fittings on the models were expressed with mathematical formulas. With the obtained information, it was detected that the best result was attained from 420x500 flask system. As a result of this method,1/2 '', 3/4 '', 1 '', 11/2 '', 2 '' fittings which are mass produced at the company were reviewed and adjusted. Thus, 90% of the production was optimized. Overall weights of scrap were reduced to 118,496 kg from 246,660 kg. Amount of error is decreased by shaping of products due to TSE standards and weights of products were decreased by 8-20%. New flask system took support of patent form TUBITAK and it was found suitable for patent in Russia with the name of "Flask model of fittings"(Patent nu: 2013/00806).
Açıklama
WOS: 000447837400005
Anahtar Kelimeler
Optimization of production, casting, amount of runner, fittings
Kaynak
Journal Of Polytechnic-Politeknik Dergisi
WoS Q Değeri
Scopus Q Değeri
Cilt
20
Sayı
3
