MANUFACTURING

PROCESSES USED IN

MAKING AN ENGINE

-SIDDHARTH SHARMA(2012B1AB198H)

-MUKESH REDDY (2012B1AB746H)

-SANCHAY BAPAT(

-HEMANTH VARMA(

-MITHILESH MUNDHADA(

HOW TO MANUFACTURE AN

ENGINE??

Components covered in this presentation :

1. Engine Block

2. Pistons

3. Crank shafts

4. Gears

ENGINE BLOCK

•Main structure which gives space for cylinders

•traditionally used raw material is cast iron alloys

•presently aluminium alloys are used because of its

low weight

319 aluminium alloy contains

85.8 - 91.5 % of aluminium

5.5 - 6.5 % of silicon

3 - 4 % of copper

0.35% of nickel

0.25% of titanium

0.5% of manganese

1% of iron, 0.1% of magnesium, and 1% of zinc.

Process used: casting

CRANK SHAFTS

•converts the force created by the engine's pistons

moving up and down into a force that moves the

wheels in a circular motion so the car can go forward

•A pressure of 200 bar acting on a 4.00 inch diameter

piston produces a force of 36,442 pounds.

•steel alloys are the solution to the problem

Medium-carbon steel alloys, composed of

predominantly the element iron and contain a small

percentage of carbon.

•Main processes : casting , forging , turning, drilling

GEARS

•Used in transmitting power and motion

•High tensile strength to prevent failure

against static loads

•High endurance strength to withstand dynamic

loads

•Low coefficient of friction

•Good manufacturability

•Processes used - Gear forming , Form milling,

Broaching

PISTONS

•Used for compressing the gases through upward and

downward movement

•Commonly used materials for pistons are cast iron,

cast steel, forged steel, cast aluminium alloys and

forged aluminium alloy. Advantages

of Aluminium over cast iron: High thermal conductivity

(approx 3 times that of cast iron).

•Processes – forging , cutting , drilling , milling , finishing

Engine Block Manufacturing

Properties

Strength

Modulus of Elasticity

Abrasion Resistance

Corrosion Resistance

Low Density

Thermal Expansion

Thermal Conductivity

Types of Materials

Gray Cast Iron Alloys

Compacted Graphite Cast Iron

Aluminum Alloy

Magnesium Alloy

Gray Cast

Iron Alloy

Compacted

Graphite cast

Al-Alloy

A356-T6

Mg-Alloy

AMC-SC1

Tensile Strength 160-320 MPa 300-600 MPa 215 MPa 117 MPa

Modulus of Elasticity 96-110 MPa 170-190 MPa 74.5 MPa

Casting1.Green Sand Molding

Zircon Sand(ZrSio4),Clay and Water

Molds made up of sections called CORES

Mold is compacted by squeezing and jolting

Also has 17 other cores

Molten Alloy is poured into it from bottom

Heat Treatment

Grinding

Quality Measures

Strength of Sand

Permeability in the size of grains

Thermal stability of Mold

Reusability

Cooling rate

GEAR MANUFACTURING

Gears are among the most important of all machine

elements because of their capability for transmitting

motion and power.

Two principal methods of gear manufacturing include Œ:

- gear forming and

- gear generation.

Gear forming :

The cutting edge of the

cutting tool has a shape identical with the

shape of the space between the gear teeth.

Two machining operations, milling and

broaching can be employed to form

cut gear teeth.

Form milling:

In form milling, the cutter called a

form cutter travels axially along

the length of the gear tooth

at the appropriate depth to produce

the gear tooth.

Broaching:

Broaching can also be used to produce gear teeth

and is particularly applicable to internal teeth. The

process is rapid and produces fine surface finish with

high dimensional accuracy.

Gear generation:

- The tooth flanks are obtained (generated) as an outline

of the subsequent positions of the cutter.

- Two machining processes are employed, shaping and

milling.

Gear hobbing:

- machining process in which gear teeth are progressively

generated by a series of cuts with a helical cutting tool

(hob).

Shaping with a pinion-shaped cutter

- The cutter axis is parallel to the gear axis.

- The tool is called gear cutter and resembles in shape

the mating gear from the conjugate gear pair, the

other gear being the blank.

- High dimensional accuracy achieved and the not too

expensive tool.

Shaping with a rack-shaped cutter

- Gear teeth are generated by a cutting tool called a rack shaper.

- Rack shaper reciprocates parallel to the axis of the gear axis.

- Involve a very high dimensional accuracy and cheap cutting tool.

- Used for low-quantity as well as high-quantity production of spur and helix external

gears.

Finishing operations:

Several finishing operations are available, including the conventional process of shaving, and a number of abrasive operations, including grinding, honing, and

lapping.

Manufacturing of Piston

Manufacturing of Piston –

THE ROD

• An Aluminium rod is cut into smaller

pieces called slugs by a Rotary saw

Forging

Preheated Punch Press punches a preheated slug forging it into the

basic shape of a piston

This process generates a lot of heat, so the piston must be air cooled for one hour.

Cutting/Drilling

A lathe is then used to cut excess metal from the basic form ,

impresses three rings ,taking it closer to its finished shape.

Tiny holes are then drilled into the sides, to create the oil passages for the piston.

Drilling- Wrist pin holes

A large hole is then drilled through both sides of the piston. This is

where the wrist pin will go, which is used to attach the piston to the

connecting rod during engine assembly.

Milling

A milling machine then shaves up to a couple of centimeters off of

each side of the piston where the large holes were drilled for the

wrist pin insertion and also near the rings.

Finishing

Lathe shaves a few more milli meters off of the top, allowing the

piston to expand when heat builds up inside of it.

A human worker then smooths out the sharp edges of the piston created during production.

Finally, the pistons sprayed by hot, deionized water, removing any

lubricant or oil gathered through the manufacturing process. After

they're dry, they're ready for use.

Finishing

Manufacturing of Cam -Shafts

Manufacturing Process Explained Graphically

1) Shaping on the lathe :

2) Process to mill the pin :

1) The process to mill the weight :

4) Conditioning quality and shot peening :

5) Shaping on the lathe for the 2nd time :

6) Process to mill the pin :

7) The oil hole, the key slot, and the bolt hole processing :

8) The pin and the journal polishing process :

9) The dynamic balance adjustment process.

10) The pin and the journal wrapping process.

11) The surface treatment process.

12) The final wrapping, bend correction, and inspection process.

Tooling Required

To produce a crankshaft there are few main tools required:

1) Lathe machine.

2) Shaper.

3) Precision Drills.

4) Milling machine.

Manufacturing of Camshaft

METHODS OF MANUFACTURING:

1. CASTING: More chances of casting defects such as shrinkage defect, porosity, crack, insufficient

pouring.

2. FORGING:

• used for certain high loaded diesel engines.

• produced on computer-controlled forging systems with integrated heat treatment or machined

from steel bar.

3. MACHINING:

A detailed description of the processes for mass manufacturing is as follows:

1.TURNING & DRILLING: The raw forging is put in this machine

and center drilling and turning on one side

is done here.

2. TURNING: Here the turning of the journals takes place. Also,

Grooving and Parting operation is performed on the left side of

the shaft.

3. DRILLING: This machine drills the hole which is used as reference for

further operations.

4. GRINDING JOURNALS: Here grinding and finish

grinding of the journals takes place.

Carborundum wheels are used for grinding

5. GRINDING ON FACE: An angular grinding wheel is used for the face

grinding operation. At this stage, inspection is done after every 10

components using gauges

6. LAPPING: To give superfinish in microns, lapping is done using lapping

paper on the Cams and the Oil seal area.

7. SLITTING: This machine makes a slit in the right side of the shaft to fit in

the engine. The cutter used is a Saw cutter and pneumatic deburring is

done here.

8. AIR & WATER CLEANING: This is the Washing Machine where water and

air jets are used to clean the component of dust, oil, chips etc.

9. INSPECTION: This is a Measuring Machine used to check for

tolerances - Runouts and Diameters of journals. The machine then declares the

component as OK, NG, or BAD.