INTRODUCTION

Federal-Mogul Corporation is a global manufacturer and supplier of power train components and vehicle safety products. The company’s products are used by original equipment manufacturers and servicers of automotive, commercial, aerospace, marine, rail and off-road vehicles; and industrial, agricultural and power-generation equipment.

Federal-Mogul operates two independent business divisions, each with a chief executive officer reporting to Federal-Mogul’s Board of Directors.

Federal-Mogul Power train designs and manufacturers original equipment power train components and system protection products in the United States and Internationally, including engine bearings, pistons, piston pins, piston rings, cylinder liners, valve seats and guides, transmission products, technical textiles and connecting rods.

Federal-Mogul Motor parts sells and distributes products under more than 20 brands in the global vehicle aftermarket, including ANCO wiper blades; Champion spark plugs, wipers and filters; AE, Fel-Pro, Goetze, Glycol and Payen engine products; MOOG steering and suspension parts; and Ferodo and Wagner brake products.

HISTORY

The company was founded in Detroit in 1899 by J. Howard Muzzy and Edward F. Lyon as the Muzzy Lyon Company. Muzzy and Lyon went into business together producing mill supplies and rubber goods. In addition, the partners formed a subsidiary called Mogul Metal Company where they launched various bearing innovations. To fit consumer needs, the pair began producing bearings made from their own Babbitt metal called "Mogul", an alloy of tin, antimony and copper. The product was trademarked under “Mogul” and “Duro” In addition to Babbitt metal, Muzzy and Lyon were also known for inventing the process of custom die-casting bearings to suit proper size and shape.

The Muzzy Lyon Company bearings business proved successful and in the early 1900s and became the pair's main concern, with Buick as one of their earliest customers. The Muzzy Lyon Company later merged with an engine bearings and bushings manufacturing company, Federal Bearings and Bushings Corporation. Federal Bearings & Bushings Co. was founded in 1915 by a group of Detroit businessmen. The company initially consisted of Mogul Metal, and Federal and Bower Roller Bearing Co. but later merged in 1924 to form Federal-Mogul-Bower Bearings, Inc.

The group established a research division with the help of Battelle Memorial Institute in 1929. During the depression, Federal-Mogul Corp. invested in the Equi-Poise propeller division. The companies continued advancements in the propeller industry were recognized in 1941, when Federal-Mogul was named the world’s largest manufacturer of motorboat propellers.

In 1955, the company acquired National Motor Bearing Company, resulting in a company name change to Federal-Mogul Bower. In addition to acquiring another company, Federal-Mogul Bower was listed as #350 on the Fortune 500, with total sales of $100 million the following year, To further Federal-Mogul Bower expansion, the company opened business operations in Switzerland, shortly after, the company opened established their first overseas service centre in Antwerp, Belgium in 1962.

In 1966, Federal-Mogul Corporation relocated from downtown Detroit, establishing its corporate headquarters in Southfield, Michigan.

In 1981, Federal-Mogul Arrowhead parts were implemented in the NASA space shuttle launch. That same year, the company won a claim in the Supreme Court to patent a process for curing rubber based on the mathematical equation written by Swedish chemist Svante Arrhenius in 1889.

In 1998, the company acquired Cooper Industries and brands including Anco wiper blades, Champion ignition, MOOG chassis, Wagner and Abex friction, and Wagner and Blazer lighting. That same year, Federal-Mogul also acquired Turner & Newall, a building materials company based in Manchester, UK.

PATIALA PLANT

Manufacturing facilities:

The Patiala plant is located in the north of India about 250 km from the capital- NEW DELHI. It is connected by road and rail routes. This plant manufactures a wide range of pistons, piston rings, cylinder liners and light alloy castings.

Products manufactured:

Pistons Piston rings Cylinder Liners Light alloy castings Molly coating

PRODUCTION CAPACITY: 13 million pistons per annum

PRODUCT RANGE: 30 mm to 300mm diameter

APPLICATIONS:

Bi-wheelers Cars SUV’s Tractors Light commercial vehicles Heavy commercial vehicles Heavy output locomotive diesel engines Stationary engine Industrial

PRODUCTS SUITABLE FOR:

4 stroke engines 2 strokes engines Gasoline engines Diesel engines

CNG engines

COATINGS:

Graphite Tin Phosphate Anodising

PISTON RING MANUFACTURING

Grey cast iron and steel piston rings are manufactured in different processes. At Federal-

Mogul grey iron piston rings are cast as individual rings in a noncircular shape. The rings are

generally machined to the required shape by means of double cam turning, a process in which

the ring blank, already axially ground is copy turned simultaneously on the inside and outside

diameters. After a segment equivalent to the free gap is cut from the ring it assumes the free

shape that will give it the required radial pressure distribution when fitted into the cylinder.

Once inside the cylinder the ring is completely light tight on its outside diameter, than it

exerts the predefined radial pressure against the cylinder wall.

Besides using double cam turning, ring blanks can also be shaped by machining the inside

and outside diameters separately. This involves cam turning the outside diameter of the

noncircular blank and machining the inside diameter with the ring in the compressed state.

The gap is cut out in a step between O.D. and I.D. machining. Heat forming as a means of

shaping piston rings should be mentioned to complete the range of options, but this process is

seldom used.

Steel piston rings are made from a profiled wire. The rings are first coiled into a circular

shape and then the gap is cut out. The necessary shape is obtained using a heat treatment

process in which the rings are mounted onto an arbour appropriately designed to impart the

required radial pressure distribution.

Profiling of the running faces of taper faced, Napier and slotted oil rings is carried out,

depending on the ring design, on automatic O.D. lathes or profile grinding machines using

special profile cutting tools before or after coating.

GENERAL PRINCIPLES

Piston Ring Functions and Operation:

Piston rings are metallic seals and have the function of sealing the combustion chamber from the crankcase and assuring the flow of heat from the piston to the cylinder. Other functions are to prevent the oil not needed for lubrication from passing from the crankcase to the combustion chamber and to provide a uniform oil film on the cylinder bore surface.To achieve these piston rings must be in contact with the cylinder wall and piston groove side. Radial contact is generally achieved by means of the inherent spring force of the ring. Fig. 1 shows the forces acting on the piston ring and Fig. 2 the most important terminology used.Gas pressure in the combustion chamber augments both the radial and the axial contact in the piston ring groove, i.e. the action of the gas pressure increases the sealing capability of the piston ring. Axial contact can alternate between the top and bottom side of the groove owing to the interaction of gas, inertia and forces. The operational characteristics of piston rings, i.e. faultless sealing against Combustion gas and lubricating oil, are contingent on the engine design, the thermal and combustion-related dynamic loading, the cylinder design and finish, the piston, the lubricating oil used, the fuel and, most significantly, the quality and design of the rings themselves.

Besides service in the piston cylinder system of internal combustion engines, piston rings are employed as metallic seals for rotating shafts and used both as contracting and expanding seals.

 

Forces acting on piston (Fig-1)

Piston ring nomenclature (Fig-2)

PISTON RING TYPES

COMPRESSION RINGS

The main functions of compression rings are to seal the combustion chamber from the

crankcase and transfer heat from the piston to the cylinder. However, they also play an

important part in controlling engine oil consumption.

There are the following types:

1. Rectangular Ring:

A piston ring with a rectangular cross section. This ring

with its geometrically simple shape performs the necessary

sealing functions under normal operating conditions. With

a peripheral coating and appropriate barrel face the

rectangular ring is today used mainly in the top groove in

passenger car gasoline and diesel engines.

2. Taper Faced Ring:

Owing to the tapered running face the ring contacts the

cylinder bore with its bottom outer edge. This shortens

running-in and improves oil scraping. The gas forces

acting initially at the running face provide a degree of

pressure relief (especially when used in the top groove).

3. Internally Bevelled or Stepped Ring:

By providing an edge relief on the top side of rectangular

and taper faced rings a twist effect is achieved which, in all

operating phases without gas pressure loading, brings the

ring into bore contact only with its bottom outer edge

while the inner edge contacts the bottom groove side

(positive twist). This helps to improve oil consumption

control.

4. Taper Faced Ring with Inside Bottom Bevel or

Step:

In the installed condition this edge relief causes a negative

twist, i.e. in the opposite direction to a ring with the relief

on the top side.

The effect of the negative twist is to make the ring contact

the groove and create a seal with its outer bottom side and

its inner top side.

5. Keystone Ring:

A compression ring with a wedge cross section. With its

tapered sides, radial movement of the ring in engine

operation will cause the axial clearance in the groove to

increase and decrease.

6. L-Shaped Compression Ring:

This ring is used mainly in small 2-stroke gasoline engines

as a "head land" ring, the vertical arm of the L being flush

with the top edge of the piston crown. With gas pressure

acting behind the vertical arm, this ring will also seal when

in contact with the top side of the piston groove.

OIL RINGS

Single-Piece Oil Control Rings

Single-piece oil control rings - like for example compression rings - derive their

tangential force from their inherent inner tension. There are the following types:

1. Slotted Oil Control Ring:

A slotted oil control ring with two outer lands, the

sides of which are parallel to one another. As the

width of the lands is smaller than the overall width a

higher unit pressure can be obtained than with a

rectangular ring.

2. Bevelled Edge Oil Control Ring:

To obtain still higher unit pressures than with a slotted

oil control ring, this type of ring has the outer lands

chamfered on the outer edge.

3. Double Bevelled Oil Control Ring:

On this type both lands are chamfered on the edge

facing the combustion chamber. While the unit

pressure is the same, oil consumption is reduced

through the improved oil scraping effect.

Multi-Piece Oil Control Rings

Two-Piece Oil Control Rings:

Two-piece oil control rings consist of a cast iron or profiled steel ring and a coil spring. The

spring is a cylindrical coil spring made from heat-set resistant spring steel and it acts

uniformly around the whole of the ring circumference.

The retaining groove for the coil spring may be semicircular or V-shaped. The coil spring

groove has the effect of reducing the moment of inertia. Where greater durability is required,

such as in diesel engines, the springs are centre less ground, sometimes additionally wound

more tightly at the ring gap and in many cases sheathed in a Teflon tube in the ring gap

region. These features have the purpose of reducing secondary wear between the spring and

ring.

In order to prevent oil from accumulating between the two outer lands, drainage holes are

provided. These can be either circular or slotted. For a long time the slotted hole was

preferred but today round holes are again being used increasingly. The drilled rings have

better breaking strength than the slotted type, offering greater safety in assembly especially

for narrow width rings. Additionally, drilled rings have a more even outer contour, which

assures better oil scraping. The cast iron rings described below can all be produced optionally

with drilled or slotted holes.

1. Coil Spring Loaded Slotted Oil Control

Ring:

A slotted oil control ring with two outer lands, the

sides of which are parallel to one another. Compared

to the slotted oil control ring described above, this ring

additionally has a groove on the inside diameter to

accommodate the coil spring.

2. Coil Spring Loaded Bevelled Edge Oil

Control Ring:

Consists of a ring similar to the bevelled edge ring, but

has an additional groove for the coil spring.

3. Nitride Profiled Steel Ring:

A bevelled edge ring made from a high-chromium

profiled steel. Wear protection is provided by nitrating

the ring all over.

ALUMINIUM PISTON MANUFACTURING PROCESS

Incoming Raw Material:

Aluminium Alloy in its various grades is procured from the secondary smelters, who alloy the primary aluminium ingots to specifications as per national and international standards.The vendors for aluminium alloy are selected on the basis of Quality and timely deliveries. The vendors are periodically evaluated for Quality, Consistency and On time deliveries.  Raw Material Grade: All incoming raw-materials (Aluminium Alloys) are subject to Optical Emission Spectrometer Analysis to determine metallurgical contents of various alloying elements. Strict compliance to national and international standards of aluminium alloys is maintained prior to accepting the raw material.  

Machining process:

Open end bore machining Rough outer diameter turning Grooves forming Semi finish hole boring Circlip grooving oil hole drilling in 3rd groove and skirt Ring grooving and chamfering Final outer diameter turning Deburring and cleaning Tin coating Finish pin hole boring

CNC Turning:

Turning of the casting is carried out on CNC machinery. This equipment is the most accurate and fastest available for this application with very tight tolerances and extremely fast spindle speeds. The following operations are performed on this machine

Open end bore machining Rough outer diameter turning Grooves forming

Reaming:

The final machining process for the piston is that of reaming. This process involves the piston being placed in a bath of oil and reamed at different sizes to reach the final size required.

Since the pin boring process is only rough it is necessary to ream the pin bore a number of times to achieve the surface finish and size required.

Piston Foundry:

Casting aluminium for today’s Hi-Performance pistons is a demanding science. All castings are cast on Semi Automatic & Fully Automated die casting machine in multipart permanent steel moulds. Melts are subject to modification, nucleation, degassing, etc. using FOSECO fluxes. Melt preparation varies from different alloys. Dies-Mould and molten aluminium poring temperatures are strictly monitored to achieve consistent casting quality. Dies and castings are periodically subject to detailed inspection and decision to replace existing die taken.  

 

Heat Treatment:

All pistons castings are subject to Solution Treatment and Precipitation. Forced Air Circulation furnaces with sophisticated programmable temperature controllers are employed

for Heat treatment. Heat Treatment chart recorders establish traceability of every batch.The solution and precipitation cycle varies for different components on the basis of alloy used, section thickness of the components, physical requirements etc.

 

Inspection of Physical Properties:

All heat-treated casting batches ate inspected for hardness requirements. Castings not complying with the specified hardness requirements are sent for heat treatment again. Periodically as per inspection plan the castings are inspected for physical properties i.e. tensile and elongation.

Machine Shop:

All pistons manufactured are machined on dedicated CNC & special Purpose Machines, which delivery high accuracy, consistency and repeatability. Close tolerances are maintained

throughout via Automatic machining and Statistical Process Control. Full automation is instituted wherever it is consistent with improvements in cost and quality. Pistons are subject to In-Process inspection as per Quality plan and Necessary corrective and preventive actions taken on the basis of the findings.  

       

Inspection:

The company has Standard room equipped with measuring equipments to measure almost all parameters of pistons with greater degree of accuracy. All pistons are subject to 100% visual inspection and dimensional inspection of critical parameters. The Company employs the use of Air Electronic Gauging and Electronic Comparators with read-out systems capable of measuring to an accuracy of 0.0002mm. (Least Count). All the measuring and test equipments are sent for Calibration to NABL Accredited Laboratory as per the calibration plans. 

 

Component Cleaning: The piston are thoroughly cleaned and degreased on fully automated washing machine using water-soluble solvents. The components are oven dried and each batch of pistons checked for proper cleaning. 

 

Surface Coatings:

Surface coatings are a special process. These processes are established through process validation. Special process parameters are strictly adhered. Surface coatings include.

Tin Plating Graphite Coating Hard Anodizing

Inspection and Grading: The pistons are subject to visual inspection and grading as per customers requirements. The pistons are graded for size and weight as specified by the customer. The pistons are colours coded or sizes engraved on the pistons crown for clear identification at the time of assembly at the customers end. 

 

Packing & forwarding:

All the pistons are packed into single or partitioned corrugated boxes. The packing is so designed that there is no contact between two components. These boxes are put in sturdy wooden cases to prevent damage during transportation. VCI Paper or VCI Oils are used specific to customer’s requirements.The company as per customers request handles forwarding. The selection of the freight carrier is based on the destination and the cost of transportation, as mutually agreed with the customer.    

VARIOUS MACHINES IN TOOL ROOM

CNC SECTION

Milling machine HMT FN2U

Pedestal grinder

MILLING SECTION

Milling FN3 vertical

TURNING SECTION

Centre Lathe

CAM Turning

TOOL AND CUTTER GRINDING SECTION

Lapping machine

Rimming

FITTING SECTION

Drill machine

PISTON MANUFACTURE

A piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. In a pump, the function is reversed and force is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder.

TYPES OF PISTON

1. Trunk pistons :

Trunk pistons are long, relative to their diameter. They act both as piston and as a cylindrical crosshead. As the connecting rod is angled for part of its rotation, there is also a side force that reacts along the side of the piston against the cylinder wall. A longer piston helps to support this.

Trunk pistons have been a common design of piston since the early days of the reciprocating internal combustion engine. They were used for both petrol and diesel engines, although high speed engines have now adopted the lighter weight slipper piston.

A characteristic of most trunk pistons, particularly for diesel engines, is that they have a groove for an oil ring below the gudgeon pin, not just the rings between the gudgeon pin and crown.

2. Crosshead pistons:

Large slow-speed Diesel engines may require additional support for the side forces on the piston. These engines typically use crosshead pistons. The main piston has a large piston rod extending downwards from the piston to what is effectively a second smaller-diameter piston. The main piston is responsible for gas sealing and carries the piston rings. The smaller piston is purely a mechanical guide. It runs within a small cylinder as a trunk guide and also carries the gudgeon pin.

Because of the additional weight of these pistons, they are not used for high-speed engines.

3. Slipper pistons:

A slipper piston is a piston for a petrol engine that has been reduced in size and weight as much as possible. In the extreme case, they are reduced to the piston crown, support for the piston rings, and just enough of the piston skirt remaining to leave two lands so as to stop the piston rocking in the bore. The sides of the piston skirt around the gudgeon pin are reduced away from the cylinder wall. The purpose is mostly to reduce the reciprocating mass, thus making it easier to balance the engine and so permit high speeds. A secondary benefit may be some reduction in friction with the cylinder wall, however as most of this is due to the parts of the piston that are left behind, the benefit is minor.

Defects:

Since it’s a main reciprocating part of engine and hence it creates the problems of unbalancing due to its inertia. Due to friction between wall of the cylinder and piston rings its life becomes short and it generates the unpleasant sound due reciprocating mechanism. To transmit the energy of reciprocating piston, it is connected to a connecting rod and crank mechanism and due to these parts there occurs mechanical losses. The motion of the crank shaft is not smooth, since energy supplied by the piston is not continuous and it is impulsive in nature. To supply the fuel into the cylinder there is need of the valves and valve mechanism and during opening and closing of the valves, mechanical noise occurs and also mechanical vibration.

MEASURING INSTRUMENTS

Vernier calliper Dial gauge

Dial vernier calliper Digital verneir calliper

Lever dial gauge Micrometer

Pitch gauge Steel scale

CUTTING TOOLS

Module cutter DP cutter

Slitting cutter Drilling cutter

Dove tail cutter Right hand tool

Boring tool Knurling tool

Filling tool End mill

ACKNOWLEDGEMENT

Before getting into thick of things, I would like to point that it was a great pleasure and privilege for me as a mechanical engineering student to have got the opportunity of undergoing training at FEDERAL MOGUL GOEZE INDIA LIMITED for a period of six weeks. I would like express our unfeigned appreciation to MR. MANJEET SINGH LANDAR and all other authorities of our college for creating the opportunity to undergo six weeks industrial training.

I am extremely thankful to MR. SILAS SINGH, who were instrumental in creating an

opportunity and under their able guidance it was possible to understand all the things in this

esteemed organization.

I would like to express my sincere gratitude to my faculty guide Dr. N.K BATRA (HOD,

Mech. Engg. Deptt. MMEC, MULLANA) for the encouragement & guidance that he gave,

under whose guidance it was able to successfully complete the work.

I am, sure that knowledge and information that I have gained during this period would be of immense value for the growth in the field of production, industrial, management and safety.

PARMINDER SINGH

11115273

B-Tech, ME

MAHARISHI MARKENDESHWAR UNIVERSITY

MULLANA, AMBALA.

QUALITY POLICY

Federal Mogul power train is committed to providing products and services that meet or exceed our customer’s requirements by maintaining a management system compliant with ISOI TS 16949, ISO 9001, or AS/EN/JISQ 9100.

We accomplish this by fostering commitment training and excellence in our people and continual improvement in our products and processes

ENVIRONMENTAL HEALTH AND SAFETY

FMGIL Patiala plant is committed to clean & conserve environment for sustainable development, to provide safe & healthy work environment to their employee, visitors, contractors and customers in relation to its operations & associated activities, through prevention of occupational injuries, illness & continual improvement of work environment .We commit for the guiding principles.

Conserve resource, reduce wastage and introduce technology, processes and materials that are environment friendly and safe.

Implementation of Aspects, Impacts, Hazard identification & Risk assessment.

Comply will all be applicable.

Raising Environment, Occupational health & Safety awareness through continual, training.

Establish & maintain Emergency management plan.

Audit & monitoring for Assessing EHS continual improvement.

TOTAL PRODUCTION MAINTENANCE

We at FMGIL Patiala to improve operations to achieve high efficiency with total employee participation through TPM (Total production Maintenance) in a safe working environment which makes us competitive in business by enhancing productivity, Quality and reducing cost.

Together we excel

5(S) PLAN

1st (S): SORT

Clearly distinguish needed items and eliminate the later

2nd (S): SET IN ORDER

Arrange the necessary item in a proper order so that they can be easily picked up for use.

3rd (S): SHINE

Clean your workplace completely so that there is no dust anywhere.

4rth(S): STANDARIZE

Maintaining a high standard of housekeeping at all times.

5th(S): SUSTAIN

Train people to follow good housekeeping discipline independently.

5 (S) ACTIVITIES

THREE- MINUTE

Check your own clothing.

Check for any leakage or droppage and pick up any parts, trash on the floor.

Wipe the temperature table’s .Position the marking and other important places.

Wipe up any water oil or whatever that may have spilled or leaked.

Reliably any things is out of plan

FIVE- MINUTE

Clean up the plates and label and make sure they are clearly legible.

Wipe the main places on the machining with ray.

Make sure all of the bits and tools are where they should be.

Get rid of anything that is not needed there.

TEN-MINUTE

Wipe the key parts and other places on the machining with ray

Fix any labels that might be coming off.

Clean the floor.

Get rid of trash in the trash bins

Check the labels, instructions and oil inlets and for anything that is amiss.

TOOL ROOM

LABOUR DATA OF TOOL ROOM

HEAD OF DEPARTMENT: Mr. Arvind Ghai

INCHARGE: Mr. Daya Singh

SHIFT SUPERVISOR: 2

STAFF: 1

APPRENTIX: 3

CASUAL LABOUR: 3

TOTAL EMLOYEES: 40

AVERAGE QUALIFICATION OF WORKERS: ITI

TOOL ROOM MOTO

“ALL PRODUCTION SHOPS ARE OUR CUSTOMERS

THEIR SATISFACTION IS OUR CONTINUAL TARGET”

TOOL ROOM ACTIVITIES

PRODUCTION TOOLING FOR ALL SHOPS

Tool room provides service to various departments. In tool room same copy of machine can be created .So the tools which are used in other departments are manufactured by tool room. In tool room the factory makes four types of tools.

(1) Production tools.(2) Cutting tools.(3) Machine tools.(4) Maintenance tools.

PRODUCTION TOOLS:

The production tools operating resources that are required to perform an activity an activity and can be used repeatedly. For example Production tools include jigs and fixture, measurements instruments.

CUTTING TOOLS:

The cutting devices used in machining work pieces on regular turret and vertical lathes, boring and slotting machines, planers, gear shaping machines and special machine tools. It consists of a shank compressing a head with the cutting element and a holder that secures the cutter to the machine tool.

MACHINE TOOLS:

Machine jobs are the jobs which are the parts or accessories of the machines which are used in factory like gears, pulleys etc.

MAINTAINANANCE TOOLS:

The activities required or undertaken to conserve as nearly and as long, as possible the original condition of a machine or resource while compensating for normal wear and tear, so the tools used for maintenance of machines are known as machine tools.

MISCELLANEOUS JOBS:

The jobs which are not production or not machine but repaired by tool room are known as miscellaneous jobs.

MODEL PLATES

The model is made of cast iron. It is hard and heavy in handling. In construction of model plate first of all thickness is maintained according to the drawing. The model plate is kept firstly on shaper machine. After getting the desired thickness that is from 20mm to 25mm the plate is kept on boring machine to make plate right angled from all sides.

Next step is to do marking of model plates, this marking is done so that no air gaps should remain in model plates. Marking is done by using 90 degree V- shaped cutter and it is done with more efficiency and has good surface finish. When rings are made with model plates there is a pressure exerted air gaps can be formed. This marking prevents the formation of air gaps from the ring and can reduce the life of ring.

SAMPLE PISTON DIES

Pistons are made in piston foundry of die-casting. Die-casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an infection mold during the process. Most die castings are made from ferrous metals specially zinc, copper, aluminium, magnesium, lead, pewter, and tin based alloys. Depending on the type of metal being cast, a hot or cold chamfer machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the processes to high volume production manufacture of parts using die casting is relatively simple, involving only four main steps , which keeps the medium sized casting, which is why die casting produces more casting than other casting process . Die casting are characterized by a very good surface finish (by casting standard) and dimensional accuracy.

Two variants are pore-free die casting which is used to eliminate gas porosity defects and direct injection die casting, which is used with zinc casting to reduce scrap and increase yield.

PROCESS FLOW CHART

RECEIVE JOB CARD STUDY DRAWING/REQUIRINMENT

ASSES MAETRIAL AND TOOLING

PLAN PROCESS

*TURNING*MILLING

*GRINDING*FITTING

INSPECTION

DELIVERY TO SHOPS

TOOL ROOM SERVICE PROVIDE TO SHOP

DEPARTMENTS

Piston Machine Shop (Domestic).

Piston Machine Shop (Exports).

Piston Machine Shop New (LVD plant).

Piston Foundry.

Piston Foundry(Export)

Pin Plant.

Heat Treatment Shop.

Ring Packing.

Piston Packing.

Ring Machine Shop.

PREFACE

An Industrial training is a golden opportunity for learning and self-development. In 6 weeks

industrial training program, every student has to undergo internship program in his field for

deep understanding of the concepts involved. I have the privilege of receiving my internship

in FEDERAL MOGULE GOETZE INDIA LIMITED.

During my industrial training I have done the study of Piston, Piston rings manufacturing.

Being a student the internship program contributed me a lot in gaining practical knowledge

about the practical engineering environment. It gave me insight into the working on

manufacturing plants and also enabled me to supplement with practical knowledge as

working.

The enclosed report present the details about the operation involved in mechanical workshop

based on my observation and discussion with officers at various level and data given to me.

Lastly I would like to thank all who have wished for my success in preparing this industrial

training project. Any complaints and suggestions for the improvement of my further study

will be heartily accepted.

PARMINDER SINGH

A

SUMMER TRAINING REPORT

ON

FEDERAL MOGULE GOETZE

M.M.ENGINEERING COLLEGE, MULLANA

Submitted in partial fulfilment of

Bachelor of Engineering

Mechanical

SUBMITTED TO:

Dr. N.K.BATARA

H.O.D

M.M.E.C. MULLANA

DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC SESSION (2011 – 2015)

SUBMITTED BY:

PARMINDER SINGH

(Roll No. – 11115273)

B.TECH MECHANICAL ENGINEERING (4TH YEAR)