Jaspreet Singhtraining File

7/23/2019 Jaspreet Singhtraining File

1/92

Six Month Industrial Training Report

COMPLETED AT

FEDERAL MOGULGOETE !I" LTD#

Su$%itted in partial &ul&ill%ent o& the Re'uire%ent &or the a(ard o&

Degree o& )a*helor o& Te*hnolog+

In

Me*hani*al Engineering

Su$%itted )+,-

Name: JASPREET SINGH

University Roll No.1281217

SU)MITTED TO

DEPARTME.T OF MEC/A.ICAL A.D I.DUSTRIAL E.GG

)A)A )A.DA SI.G/ )A/ADUR E.GI.EERI.G COLLEGE

FATE/GAR/ SA/I)

1


2/92

TA)LE OF CO.TE.T

A*0no(ledge%ent

1# Co%pan+ Pro&ile

a !an"#a$t"rin% Plant in In&ia

' (o$ation o# Plant in In&ia

2# Ring Ma*hine Shop

a Introdu*tion to Ring Ma*hine Shop

' Se$tion o# Rin% !)* S+o,

$ Intro&"$tion to Piston Rin%s

& -ario"s ma$+ines in t+e Rin% !)* S+o,

3# Pro4e*t 5or0

a S$ra, Re&"$tion in moly $oate& -1 !aterialPiston Rin%s' TP! /Total Pro&"$tive !aintenan$e$ NATI0NA( PR0U*TI-IT *0UN*I( STU

2


3/92

AC6.O5LEDGEME.T

I would like to thanks the Head of training and Development at FEDERAL

-MOGULGOETZE INDIALIMITEDfor providing me the opportunity to carry out

my six weeks industrial training at FMG I!DI"# $IMI%&D 'ahadurgarh ( )atiala*

I am extremely grateful to Mr* +pkar ,ingh( head of )M, &xport and Mr*

,uresh kapoor( Manager of die inspection and Mr*-amaldeep ,ingh .uality

manager in )M, &xport( who gave me the pro/ect to exercise my knowledge and

increase the e0ciency of my personality as a whole*

nce again I would like to express my deep gratitude for all the persons

with whom I came in contact during my stay at Federal-MogulGoetz India

Limited ( without whose help my training would have ended as a heap of

unanswered .ueries*

JASREET SING!

"#$"#"%

&' Te()' *ME+!'%t)SEM',

&&S&E+

Fate)gar) Sa)i


4/92

3


5/92

Federal-Mogul Corporation

Founded 1833 as t+e !"44y5(yon *om,any.

/ead'uarters So"t+#iel&6 !i$+i%an6 USA.

6e+ people J"e$sto$ Reiner6 Presi&ent *E0.

Industr+ A"to Parts.

Produ*ts Pistons6 rin%s6 ,ins6 liners6 valve seats an& %"i&es6

i%nition ,ro&"$ts6 'earin%s6 '"s+in%s6 +eats+iel&s6 sealin% ,ro&"$ts6

transmission $om,onents6 'rae an& $+assis $om,onents6 an&

systems ,rote$tion ,ro&"$ts. Re7enue 9.3 'illion US /28

.et in*o%e ;98 million US /28

E%plo+ees ;


6/92

COMPA.8 PROFILE

>e&eral5!o%"l *or,oration is a %lo'al

s",,lier o# a"tomotive $om,onents6 systems

an& mo&"les servin% t+e =orl&?s ori%inal

e@"i,ment man"#a$t"rers an& t+e %lo'al

a#termaret. T+e $om,any "tili4es its

en%ineerin% an& materials e,ertise6

,ro,rietary te$+nolo%y6 man"#a$t"rin% sill6

&istri'"tion #lei'ility an& maretin% ,o=er

to &eliver ,ro&"$ts6 'ran&s an& servi$es

o# val"e to its $"stomers. >e&eral5!o%"l is

#o$"se& on %lo'al ,ro#ita'le %ro=t+ to $reate

val"e #or an& 'rin% %reater satis#a$tion to its

$"stomers6 em,loyees an& stae +ol&ers.

>e&eral5!o%"l Borl& Hea&@"arters is lo$ate&

at 29CCC Nort+=estern Hi%+=ay6 So"t+#iel&6

!I ;8e&eral5!o%"l &esi%n6 en%ineer an& man"#a$t"re a variety o# a"tomotive ,ro&"$ts #or its

a#termaret an& 0E $"stomers. Its ,ro&"$ts in$l"&e6 '"t are not limite& to6 'earin%s6 ,istons6 ,iston

,ins6 rin%s an& liners6 valve seats an& %"i&es6 &ynami$ seals6 +ot an& $ol& stati$ %asets an& seals6

li@"i& elastomer mol&e& /(E! seals6 systems ,rote$tion6 #ri$tion ,ro&"$ts an& a#termaret ,ro&"$ts

/en%ine $om,onents6 %asets6 anti#ri$tion 'earin%s an& seals6 'raes6 $+assis6 =i,ers6 #"el ,"m,s6

i%nition an& li%+tin%.

>e&eral5!o%"l a#termaret ,ro&"$ts are sol& "n&er a variety o# ,o=er 'ran&s6 in$l"&in%6 '"t

not limite& to6 AEF en%ine ,ro&"$ts6 AN*0F =i,ers6 *+am,ionF s,ar ,l"%s an& =i,ers6 >el5ProF

%asets6 >ero&oF 'rae ,a&s6 Gly$oF 'earin%s6 Goet4eF ,iston rin%s6 !oo%F $+assis ,ro&"$ts6

NationalF B+eel En& *om,onents6 NralF ,istons6 PayenF %asets6 Seale& Po=erF en%ine

,ro&"$ts an& Ba%nerF li%+tin% an& 'rae ,ro&"$ts. G0ETE /I (I!ITE6 AHAURGARH =as

set ", in 13C; 'y !r. H.P.Nan&a =it+ t+e $olla'oration o# !)S G0ETE BERE6 GER!AN6

=+i$+ starte& its ,ro&"$tion o# Piston Rin%s #or a"tomo'ile in&"stry in 13C7. *onsi&erin% t+e nee& o#$om,lete PIST0N assem'ly ES*0RTS (I!ITE vent"re& into man"#a$t"rin% o# Pistons. In 13C8

5


7/92

=it+ t+e $olla'oration o# !)S !AH(E6 GER!AN6 t+is &elivere& t+e In&ian a"tomo'ile in&"stry its

Piston in 139. ES*0RTS entere& in $olla'oration =it+ !)S SU06 GER!AN6 #or Piston Pins in

1397 an& man"#a$t"rin% starte& in 1398.To meet t+e in$reasin% &eman& o# maret6 in 1377 a ,arallel

"nit #or man"#a$t"rin% Pistons an& Pistons Pins =as set ", in ANG(0RE.

Te$+nolo%i$al lea&ers+i, mat$+e& =it+ innovate& t+inin% +as ma&e ES*0RTS an&

G0ETE ,ro&"$ts to enoy a +i%+ &e%ree o# $"stomer $on#i&en$e an& are t+e #irst $+oi$es o#

&is$ernin% #or a,,li$ation ran%in% #rom I5BHEE(ER to ATT(E TANS. T+e ,lant man"#a$t"re

over ari&a'a&6 aa6

Hin&"stan !otors6 T-S6 Ra&ootan& many ot+ers. T+e $om,any also &ire$tly s",,lies its ,ro&"$ts to

all t+e a"t+ori4e& &ealers o# t+e s,are ,art #or t+e a'ove $om,anies t+ro"%+o"t INIA.

>rom 1st0$to'er6 13396 ES*0RTS (I!ITE entere& into oint vent"re =it+ !)S !AH(E

Gm'H6 GER!AN =it+ t+e #ormation o# ne= $om,any6 ES*0RTS !AH(E (I!ITE. In 13386

G0ETE also 'e$ame t+e ,art o# >EERA( !0UGA(6 a =ell no=n %ro", o# U.S.A.

In J"ne 26 'ot+ ES*0RTS !AH(E (I!ITE an& G0ETE +ave 'e$ome KS 3

$erti#ie& $om,anies. Bi&e ran%e o# ,istons an& ,ins are also e,orte& to U..6 Iran6 an%la&es+6 Sri5

(ana6 E%y,t6 Sin%a,ore an& !alaysia.

In 0$to'er 29 name $+an%e& LGoet4e /In&ia (imite&M to L>EERA(5!0GU( G0ETE

/INIA (I!ITEM 'e$a"se maority stae +ol&in% a$@"isition 'y >e&eral5!o%"l *or,oration.

>e&eral5!o%"l Goet4e /In&ia (imite& is t+e lar%est man"#a$t"rer o# ,istons an& ,iston rin%s in In&ia

Pistons are varyin% #rom e&eral5!o%"l +as over 2C lo$ations6 a$ross 9 $ontinents6 in 2; $o"ntries6 =it+ C96

em,loyees =orl&=i&e. Hea&@"artere& in So"t+#iel&6 !i$+i%an6 >e&eral5!o%"l is a D7 'illion

a"tomotive ,arts man"#a$t"rer ,rovi&in% innovative sol"tions an& systems to %lo'al $"stomers in t+e

a"tomotive6 li%+t tr"$6 +eavy5&"ty6 railroa&6 #arm an& in&"strial marets. A $ent"ry o# ,eo,le servin%

$"stomers t+ro"%+ man"#a$t"rin% mastery +as ma&e >e&eral5!o%"l a %lo'al lea&er in t+e a"tomotive

in&"stry. Re$o%ni4e& 'y o"r $"stomers as t+e s",,lier o# $+oi$e #or ,o=ertrain systems6 sealin%

systems6 an& %eneral ,ro&"$ts o# lea&in% e&%e innovation an& te$+nolo%y6 >e&eral5!o%"l is a

&ynami$6 %ro=t+5oriente& $om,any &e&i$ate& to &eli%+tin% $"stomers.

6


8/92

FEDERAL MOGUL GOETE !I.DIA" LTD.5

Goet4e /I (imite&6 a+a&"r%ar+ =as set ", in 13C; =it+ t+e $olla'oration o# !)S

Goet4eBere6 Germany6 =+i$+ starte& its ,ro&"$tion o# ,iston rin%s #or a"tomo'ile in&"stry in 13C7.

*onsi&erin% t+e nee& o# $om,lete ,iston assem'ly ES*0RTS (T. vent"re& into

man"#a$t"rin% o# ,istons in 13C8 =it+ t+e $olla'oration o# !)S !a+le Gm'H6 Germany6 =+i$+

&elivere& t+e In&ian a"tomo'ile in&"stry its ,iston in 139.

ES*0RTS entere& in $olla'oration =it+ !)S SU0 Gm'H6 Germany6 #or ,iston ,ins in 1397

an& man"#a$t"rin% starte& in 1398.To meet t+e in$reasin% &eman& o# maret6 in 1377 a ,arallel "nit to

man"#a$t"re ,istons ,iston ,ins =as set ", in an%alore.

Te$+nolo%i$al lea&ers+i, mat$+e& =it+ innovate& t+inin% +as ma&e Es$orts an& Goet4e

,ro&"$ts to enoy a +i%+ &e%ree o# $"stomer $on#i&en$e an& are t+e #irst $+oi$e o# &is$ernin% $"stomer

#or a,,li$ation ran%in% #rom 'i5 =+eeler to 'attle tans.

>rom 1st0$to'er 13396 ES*0RTS (I!ITE entere& into oint vent"re =it+ !)S !a+le

Gm'H6 Germany =it+ t+e #ormation o# ne= $om,any6 ES*0RTS !AH(E (I!ITE.

In 13386 Goet4e also 'e$ame t+e ,art o# #e&eral mo"%al6 a =ell5no=n %ro", o# U.S.A. In

J"ne 26 'ot+ Es$orts !a+le (imite& an& Goet4e +ave 'e$ome KS 3 $erti#ie& $om,anies.

OPERATIO.S DO.E AT FEDERAL-MOGUL GOETE !I" LTD

PISTONS !eltin%6 Alloyin%6 *astin% !a$+inin%6 Ano&i4in%6 Ins,e$tion.

PISTON RINGS !eltin% 6 Alloyin% 6 *astin% 6 !a$+inin% 6 *+rome Platin%6 !oly *oatin% 6

Ins,e$tion.

PISTON PINS !a$+inin% 6 Heat Treatment 6 Ins,e$tion

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9/92

LANT LO+ATION

-ey industrial township in

Most prosperous state in8ell connected 9y rail:road

&!I.ADI

Industrial township in ;a/asthan

)roximity to

$ocated on key highway

>apital city of

?s I% Hu9

8ell connected across

/ISTOR8 OF GOETE 5ER6E

OCATIO. OF PLA.T I. I.DIA

@

13C; In$or,orate& as a J- =it+ Goet4eBere

13C7 Rin% (iner Pro&"$tion Patiala13C8 Piston Pro&"$tion as Es$orts /A"tomotive

ivision /*olla'oration: !a+le

Patiala

139*ast Iron ) >or%e& Piston Pro&"$tion

Starte&

Patiala

1398 Pins ) Rin% *arrier Pro&"$tion starte& Patiala

1377 Piston ) Rin% Pro&"$tion starte& an%alore

1382 Steel Rin%s ) (ar%e ore (o$omotive Piston an%alore

138C (i%+t Alloy Pro&"$ts Patiala

1383 A"to T+ermi$ Pistons Pro&"$tion an%alore

133 !oly $oate& ) IA ) *+rome 0il Rin%s Patiala

1332 (ar%e ore Rin%s ) Pistons #or attle Tans an%alore

133; *om,osite Pistons ) Ne= Rin% >o"n&ry an%alore

1339 Es$orts /A"tomotive ivision +ive& o## into oint vent"re =it+ !)s

!a+le6 Germany

1337 Goet4e TP /In&ia (t&. set", #or man"#a$t"re o# Steel Rin%s

2!er%er o# >e&eral5!o%"l Sintere& Pro&"$ts (t&. =it+ Goet4e /In&ia

(t&.


10/92

RODUCTS MANUFACTURED AT PATIALA PLANT

1A


11/92

11

ISTONS I N SRINGS


12/92

An Introdu*tion to Piston Rings

Piston:T+e Piston is a $ylin&ri$al ,l"% t+at moves ", an& &o=n in t+e en%ine

$ylin&er. It +as t+e ,iston rin%s to ,rovi&e a %oo& seal 'et=een t+e $ylin&er =all

12


13/92

an& ,iston. Alt+o"%+ t+e ,iston a,,ears to 'e a sim,le ,art6 it is a$t"ally a very

$om,le &esi%n. T+e ,iston =ors =it+ ,iston rin%s to $ontain t+e $om,ression

an& $om'"stion ,ress"re =it+in t+e $ylin&er.

Piston Rings:A metalli$ $ir$"lar s,rin% =it+ a +i%+ relative o"t=ar& e,an&in%strain. It #its to an ann"lar %roove t+at #its its se$tion. T+e re$i,ro$atin% an&)or

rotatin% ,iston rin% seals a%ainst a ,ress"re &i##erential o# %ases or li@"i&s

'et=een t+e rin% an& a $ylin&er 'ore an& one si&e o# t+e rin% an& %roove.

Functions of Piston Rings:

T+e ,iston rin%s in I.* En%ines +ave to ,er#orm t+e #ollo=in% #"n$tions:

To #orm a seal #or t+e +i%+ ,ress"re %ases #rom t+e $om'"stion $+am'er a%ainst

lea into t+e $ran$ase. To ,rovi&e easy ,assa%e #or +eat #lo= #rom t+e ,iston $ro=n to t+e $ylin&er

=alls.

To maintain s"##i$ient l"'ri$atin% oil on t+e $ylin&er =all t+ro"%+o"t t+e entirelen%t+ o# t+e ,iston travel6 minimi4in% t+e rin% an& t+e $ylin&er =ear. An& at t+esame time6 $ontrol t+e t+i$ness o# t+e oil #ilm so t+at satis#a$tory oil $ontrol ismaintaine&. T+e oil is not to 'e allo=e& to %o ", to t+e $om'"stion $+am'er=+ere event"ally it =o"l& '"rn to leave $ar'on &e,osits.

A %oo& seal m"st 'e maintaine& 'et=een t+e ,iston an& t+e $ylin&er =all to

,revent 'lo=5'y. lo=5'y is t+e name t+at &es$ri'es t+e es$a,e o# "n'"rne& air5#"el mit"re an& '"rne& %ases #rom t+e $om'"stion $+am'er6 ,ast t+e ,istonsan& into t+e $ran$ase. T+ese %ases L'lo= 'yM t+e ,istons. T+e ,iston $annot #it

in t+e $ylin&er $losely eno"%+ to ,revent 'lo=5'y. T+ere#ore6 ,iston rin%s m"st'e "se& to ,rovi&e t+e ne$essity seal.

T+e rin%s are installe& in %rooves in t+e ,iston. A$t"ally6 t+ere are t=o

ty,es o# rin%s6 $om,ression rin%s an& $ontrol rin%s.

T+e $om,ression rin%s seal in air5#"el mit"re as it is $om,resse&. T+ey also

seal in t+e $om'"stion ,ress"re as t+e mit"re '"rns. T+e oil $ontrol rin%s

s$ra,e e$essive oil #rom t+e $ylin&er =all an& ret"rn to t+e oil ,an. T+e rin%s+ave oints so t+ey $an 'e e,an&e& an& sli,,e& over t+e ,iston +ea& an&

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14/92

%rooves into t+e ,iston. Rin%s #or a"tomotive en%ines "s"ally +ave '"tt oints.

In some +eavy5&"ty en%ines6 t+e oint may 'e la,,e&6 or o# t+e seale& ty,e.

T+e rin%s are sli%+tly lar%er t+an in &iameter t+an t+ey =ill 'e in $ylin&er.

T+en6 =+en t+e rin%s are installe&6 t+ey are $om,resse& so t+at t+e oints arenearly $lose&. *om,ressin% t+e rin%s o"ts t+em in tension. T+en t+ey ,ress ti%+t

a%ainst t+e $ylin&er =all.

T+e &istan$e 'et=een t+e en&s o# t+e rin%s =+en it is $om,resse& in t+e

$ylin&er is $alle& t+e rin% %a,.

Properties of Piston Ring

T+e ,iston rin%s m"st +ave t+e #ollo=in% ,ro,erties in or&er to ens"re t+ey

#"n$tion as re@"ire&:

1. Not loose its tan%ential tension at +i%+ tem,erat"res

2. Goo& $on&"$tor o# +eat


15/92

14


16/92

FITTI.G T/E RI.GS TO T/E PISTO.

T+is is &one =it+ +el, o# s,e$ial #it"res. Ea$+ "nne$essary removal an&re,la$ement im,airs t+e tension o# t+e rin%. I# s"'se@"ent removal an&

re,la$ement $annot 'e avoi&e&6 it may only 'e &one =it+ t+e ,iston rin% ,liers6

as 'y e$essive s,rea&in% ,ermanent &e#ormation is $a"se& an& in $onse@"en$e

t+e sealin% a$tion o# t+e rin% is a&versely a##e$te&.

PRECAUTIO.S

T+e $ylin&er 'ore m"st 'e ,er#e$tly ro"n&.

Goo& $ross +avin% =it+ ,ro,er s"r#a$e ro"%+ness is ne$essary.

S,e$ial attention m"st 'e ,ai& to %oo& l"'ri$ation /#ormation o# oil #ilm

A'sol"te $leanliness &"rin% assem'ly is re@"ire&.

I# ne$essary rin%s =it+ s,e$ial s"r#a$e ,rote$tion $oatin% s+o"l& 'e sele$te&.

Attention s+o"l& 'e ,ai& to %oo& #iltration o# t+e air an& #"el.

FITTI.G T/E PISTO. COMPLETE 5IT/ T/E C8LI.DER,

T+is ,ro$ess m"st 'e &one in s"$+ a manner t+at t+e rin%s are intro&"$e& intot+e $ylin&er 'ore =+en $om,resse& 'y a rin% $lam,in% stra, in no $ase =it+s$re= &rivers. T+e rin% %a, s+o"l& t+en 'e set o,,osite one anot+er.

15


17/92

Ring Material

T+e material %enerally "se& #or ,iston rin%s is #ine %raine& allo cast iron

$ontainin% sili$on an& man%anese. It +as %oo& +eat an& =ear resistin% @"alities.

T+e +ar&ness on Ro$=ell s$ale is a'o"t 11.

Allo steels+ave also 'een "se& as rin% material. C!ro"iu" plating

#"rt+er +el,s t+e rin%s to resist s$"##in% 'e$a"se it is &i##i$"lt to 'e=el&e& to

$ast iron $ylin&er. Ho=ever6 t+ese rin%s s+o"l& not 'e "se& =+en t+e $ylin&er

'ore itsel# is line& =it+ $+romi"m or any s"$+ +ar& material.

Rin%s =it+ "ol#$enu"%fille$ face+ave also 'een intro&"$e& re$ently.

T+e moly'&en"m s"r#a$e +as lar%er oil $arryin% $a,a$ity. It is t+ere#ore

,rovi&es 'etter $ylin&er =all l"'ri$ation =it+ res"ltant lon%er en%ine li#e. T+e

+i%+er meltin% ,oint o# moly'&en"m ena'les t+e rin% to withstand higher

temperaturest+an ot+er rin% metals an& t+"s re&"$e s$"##in%.

Stainless steel oil rin%s resist pitting and corrosionto remain $lean an&&o not $lo% =it+ $ar'on as @"i$ly as ot+er rin%s. >"rt+er6 t+ese resist excessive

tensionat en%ine o,eration tem,erat"res.

16


18/92

Tpes of Rings

Single piece rings:A rin% #orme& #rom only one ,art6 =+i$+ is inten&e&

#or installation in a sin%le rin% %roove.

Multi piece ring:A rin% $om,risin% t=o or more $om,onent ,arts6

=+i$+ are inten&e& #or installation in a sin%le rin% %roove.

Co"pression Ring:A rin% inten&e& ,rimarily to ,revent t+e leaa%e o#

%as ,ast t+e ,iston.

Oil Control Ring: a rin% +avin% oil ret"rn slots or an e@"ivalent an&

inten&e& to s$ra,e oil #rom t+e $ylin&er.

Rectangular Ring: A $om,ression rin% =it+ a re$tan%"lar $rosses

se$tionO =it+ its %eometri$ally sim,le #orm6 it ,rovi&es a&e@"ate seal

"n&er normal o,eratin% $on&itions.

&estone Ring:a $om,ression rin% =it+ 'ot+ si&es ta,ere&O it is "se& in

t+ose $ases =+en rin% sti$in% $an 'e e,e$te&. "e to its =e&%e

s+a,e6 any ra&ial movement o# t+e rin% =ill alter its aial $learan$e

an& t+"s minimi4e t+e '"il& ", o# $om'"stion $+am'er.

'alf &estone Ring: A $om,ression rin% =it+ one si&e ta,ere&O "s"ally

t+e ta,ere& si&e is t+e one6 =+i$+ t+e $om'"stion $+am'er.

Scrapper Ring(Steppe$):A rin% =+i$+ +as a ste, on t+e lo=er ,eri,+eral

e&%e to s$ra,e oil #rom t+e $ylin&er =all. It $an also a$t as a lo=er

$om,ression rin%.

Scrapper Ring(Napier):A s$ra,,er rin% =it+ an "n&er$"t ste,.

Slotte$ Oil Ring:A slotte& oil $ontrol rin% =it+ ,arallel si&es an& t=o

$onta$t lan&s o# t+is ty,e o# rin%6 a +i%+ "nit ,ress"re is a$+ieve&.

17


19/92

*e+ele$%E$ge Oil Control Ring:A slotte& oil $ontrol rin% =it+ ,arallel si&es an& t=o

lan&s. T+e ,eri,+eral e&%es o# 'ot+ lan&s are $+am#ere&. In or&er to a$+ieve a #"rt+er in$rease

in "nit ,ress"re an& t+ere'y a 'etter oil s$ra,,in% e##e$t.

Dou#le%*e+ele$ Oil Control Ring: A rin% similar to 'evele& e&%e oil $ontrol rin%6

e$e,t t+at 'ot+ lan&s are $+am#ere& on t+eir ",=ar&s #a$in% e&%es o# 'ot+ lan&s in t+e same

&ire$tion6 t+e oil s$ra,,in% e##e$t is #"rt+er im,rove&.

Coil Spring Loa$e$ Slotte$ Oil Control Ring:A rin% similar to slotte& oil $ontrol

ty,e6 t+e ra&ial ,ress"re o# =+i$+ is in$rease& 'e means o# a $ylin&er $oil s,rin%. T+is s,rin%

a$ts e@"ally in all &ire$tions a%ainst t+e insi&e o# t+e rin%.

1@


20/92

S#.o# Cross Se*tion Con&iguration o& Rings

1# Re$tan%"lar Rin%

2# eystone Rin%

3# Hal# eystone Rin%

9# S$ra,,er Rin%/Ste,,e&

:# S$ra,,er Rin%/Na,ier

;# Slotte& 0il *ontrol Rin%


21/92

T+e rin%s are %enerally o# t=o ty,es:5

*om,ression Rin%s

0il *ontrol Rin%s

T+e to, $om,ression rin% i.e. t+e rin% nearest to t+e $om'"stion $+am'er +as to &o +ar&

=or o# %as sealin% an& trans#er +eat #orm t+e o# ,iston $ro=n to t+e $ylin&er =alls. T+ey

m"st seal an& trans#er +eat an& also assist t+e oil rin%s in $ontrollin% t+e oil.

T+e #"n$tion o# t+e oil $ontrol rin% is evi&ent #rom t+eir name. To ,er#orm t+is

#"n$tion e##e$tively t+ey m"st ,revent e$essive amo"nts o# oil #rom ,assin%:

et=een t+e rin% #a$e an& t+e $ylin&er =all

T+ro"%+ t+e rin% en& %a,

Aro"n& 'e+in& t+e rin%

Co%pression Rings

*om,ression rin%s are "s"ally ma&e o# $ast iron. T+e material +as %oo& =earin%

@"alities. It also ,rovi&es %oo& rin% tension6 or #or$e6 on t+e $ylin&er =alls. Some +eavy &"ty

rin%s are ma&e o# &"$tile iron. T+ese rin%s are more #lei'le t+an $ast iron. "$tile iron rin%s

are =i&ely "se& in ra$in%6 &iesel t"r'o$+ar%e& ot+er +i%+ ,er#orman$e en%ines.

*om,ression rin%s6 'esi&es re&"$in% 'lo=5'y6 also +el, $ontrol oil. 0n t+e intae

stroe6 $om,ression rin%s s$ra,e all t+e t+in #ilm o# oil #rom t+e $ylin&er =alls. T+en on t+e

e+a"st stroe t+e rin%s are movin% ",=ar& an& ten& to sate over t+e oil #ilm.

*oatin%s o# vario"s s"'stan$es +ave 'een a,,lie& to $om,ression rin%s to +el, wear-

inan&prevent rapid wearo# rin%s an& $ylin&er =alls.

21


22/92

Oil Control Rings

T+e oil $ontrol rin% or rin%s ,revent oil #rom =orin% ", into t+e $om'"stion

$+am'er. 0il t+ro=n o## t+e main an& ro& 'earin%s l"'ri$ates t+e $ylin&er =alls6 ,istons an&

rin%s. Some $onne$tin% ro&s +ave an oil s,lit +ole6 =+i$+ s,ills oil onto t+e $ylin&er =all

every time it lines ", =it+ t+e oil +ole in t+e $ran,in.

!ost o# t+e time more oil is t+ro=n onto t+e $ylin&er =alls t+an is nee&e&. It m"st 'e

s$ra,,e& o## an& ret"rne& to t+e oil ,an. I# too m"$+ oil is le#t on t+e $ylin&er =alls6 it =ors

its =ay ", into t+e $om'"stion $+am'er6 =+ere it '"rns. T+is in$reases oil $ons"m,tion an&so t+e en%ine re@"ires etra oil @"ite o#ten. Also t+e '"rnt oil #o"ls t+e s,ar ,l"%6 +am,ers

t+e a$tion o# t+e $om,ression rin%s an& in$reases t+e ,ossi'ility o# en%ine &etonation.

T+e oil t+at is s$ra,,e& o## t+e $ylin&er =alls &oes several t+in%s. It $arries a=ay

,arti$les o# $ar'on6 &"st an& &irt. T+ese ,arti$les are t+en remove& 'y t+e oil s$reen or #ilter.

T+e oil also ,rovi&es some $oolin% e##e$t on t+e $ylin&er =all. T+ere#ore6 as t+e oil $ir$"lates

it l"'ri$ates6 $leans6 $ool an& seals.

Rin% %rooves #or oil $ontrol rin%s +ave &rain +oles or slots =+i$+ allo= t+e oil $ontrol

rin%s s$ra,e o## t+e $ylin&er =alls to &rain to t+e insi&e o# t+e ,iston. T+ere t+e oil &ro,s o##

an& #alls &o=n into t+e oil ,an. Some l"'ri$ates t+e ,iston ,in.

22


23/92

Ring Ma*hine Shop

Rin% ma$+ine s+o, is a ,ro&"$tion "nit at Goet4e In&ia (imite&6

a+a&"r%ar+. In t+is s+o, s,e$ial ,"r,ose &e&i$ate& ma$+ines are

"se& #or t+e ,ro$essin% o# rin% 'lans /rin%s o'taine& #rom #o"n&ry

to t+e #inis+e& rin%s as ,er re@"irements o# t+e $"stomer. Rin%

ma$+ine s+o, +as stren%t+ o# a,,ro. C. Some ma$+ines r"n aro"n&

t+e $lo$.

Classification of rings processe$

ase& on ty,e o# rin%

ase& on material o# rin%

ase& on $oatin% to 'e &one

1# )ased on t+pe o& ring

*om,ression Rin%s

0il *ontrol Rin%s

2# )ased on %aterial o& ring

Stan&ar& 1 material

Stan&ar& G0E51< material

Stan&ar& -1 material

Stan&ar& IA material

2


24/92

3# )ased on *oating to $e done

*+rome rin%

!oly'&en"m rin%

In Goet4e In&ia &i##erent rin%s ma&e are $ast iron rin%s or alloye&

rin%s an& steel rin%s:

Ring

Mat#

Che%i*al Co%position!in >age"

C Si Mn P Cr Cu S Mg ? Ni !o

61


25/92

Se*tions in Ring Ma*hine Shop

Rin% ma$+ine s+o, is &ivi&e& into t+e #ollo=in% se$tions:

1# Rough Se*tion

2# Finish Se*tion

3# Chro%e Se*tion

9# Mol+ Se*tion

:# C.C Se*tion

;# Coil 5inding


26/92

Ring &lan/0 1rom Foundr2

Pro*ess Flo( Chat

Rough Se*tion,

25

O3er0iUnder0ize

*S(ra4,

Grinding &e1ore

Send to Fini0)

A5ial .idt) In04e(tion

Roug) Grinding

Medium Grinding

Fini0) Grinding

Fini0) Grinding

Medium Grinding

!eat Treatment *onl2

Grinding a1ter

S4litting o1 Doule

Doule +am Turning 8 Ga4 Turning


27/92

Finish Se*tion,

26


28/92

T+e ro"%+ se$tion in$l"&es t+e aial %rin&in% o# t+e rin% 'lans re$eive& #rom t+e

,iston rin% #o"n&ry alon% =it+ t+e ,ro$ess s+eet.

!aor in#ormation o'taine& #rom t+e ,ro$ess s+eet is:

K"antity o# rin%s iss"e& an& @"antity re@"ire&

S,e$i#i$ations o# rin% 'lan)#inis+ rin%

ra=in% o# rin%

!aterial o# rin%

Se@"en$e o# o,erations to 'e ,er#orme& toleran$e to 'e maintaine& at every ste, o#

,ro&"$tion

S,e$ial ,ro&"$t $+ara$teristi$s

S,e$ial Instr"$tions an& remars

Rin% lans are $ast in @"antity lar%er t+en as ,er re@"irement tain% into s$ra,

$onsi&erations. e,en&in% on t+e ty,e o# material o# rin% an& o,erations to 'e ,er#orme& a

m"lti,lyin% #a$tor is &e$i&e& #or $astin% o# rin% 'lan. Us"ally t+is m"lti,lyin% #a$tor varies

#rom 1.C 51.1C.

lans ma&e in #o"n&ry /1.C to 1.1C K"antity re@"ire&

,- A.ial /i$t! 0rin$ing:

Rin%s o'taine& #rom #o"n&ry +ave ,oor s"r#a$e #inis+ an& less &imensional a$$"ra$y.

Rin% 'lans are %rin& aially to a$+ieve t+e &imensions re@"ire&. To %rin& rin%s aially

$enter5less %rin&in% ma$+ines are "se&. T+ese are very ro'"st6 ri%i&6 +eavy ma$+ines. In t+is

,ro$ess rin% 'lans are #e& t+ro"%+ a ma%neti$ #ee&er to t+e t=o revolvin% %rin&in% =+eels6

se,arate& 'y a &istan$e =+i$+ is e@"al to t+e t+i$ness o# t+e rin% re@"ire&.

27

+)rome

+om4re00ionOil (ontrol

Semi Fini0) Ring

1rom Rou ) Se(tion

+)rome

Ga4 Sizing

Fini0) Turning

8 Out0ide

Edge &rea/ing

Final In04e(tion

&e3eling *9)ere3er

04e(i:ed,

In0ide Groo3ing

Ga4 0izing

Fini0) Turning

Slotting

Out0ide Groo3ing

Stam4ing

In0ide +)am1ering

*9)ere3er

Final In04e(tion

Not() milling

Tra4ezoidal

Ga4 Sizing

Fini0) Turning

Stam4ing

In0ide +)am1ering

*9)ere3er


29/92

Aial =i&t+ %rin&in% is $arrie& o"t in t=o or t+ree sta%es as ,er re@"irement an&

&i##erent s,e$ial ,"r,ose6 &e&i$ate& $entre5less %rin&ers are "se& #or %rin&in% t+e rin% 'lans

to a$+ieve re@"ire& si4e as ,er ,ro$ess s+eet.

Ma*hine Grinding Stage .u%$er o&

H!T RoughMediu%

Grinding2

esley RoughMediu%Grinding:

>S Finish grinding :

ae#i% Finish grinding 1

i- 'MT1*esle Roug! grin$ing Mac!ine

Use& #or ro"%+)me&i"m %rin&in% o# aial =i&t+ o# rin%s

Borin% ,rin$i,le is $entre less %rin&in% =it+ +ori4ontal s,in&les

Parameter $ontrolle& is aial =i&t+ o# rin%

!an,o=er 2 ,ersons ,er s+i#t

An%le 'et=een %rin&in% =+eels


30/92

ii- DFS finis! 0rin$ing Mac!ine

Use& #or #inis+ %rin&in% o# aial =i&t+ o# rin%s

Borin% ,rin$i,le is $entre less %rin&in%

Parameter to 'e $ontrolle& is aial =i&t+ o# rin%s

!an,o=er 2 ,ersons ,er s+i#t

An%le 'et=een %rin&in% =+eels5


31/92

2- Splitting

It is t+e o,eration o# $"ttin% a sin%le Lo"'le lanM into t=o sin%le 'lans. T+is

o,eration is not $arrie& o"t on all ty,es o# rin%s. Us"ally t+is o,eration is $arrie& on -1

rin%s. -1 rin%s are +ar&est o# all t+e materials "se& #or rin% man"#a$t"rin% an& it is "s"ally

$ast in &o"'le 'lans6 #rom a sin%le L&o"'le 'lanM6 t=o rin%s $an 'e o'taine&.

-1 $om,osition is s"$+ t+at &"rin% $astin% maim"m metall"r%i$al an& $astin%

&e#e$ts lie sla% in$l"sion6 'lo= +oles an& ,orosity lie in t+e mi&&le o# t+e rin%. T+e

maim"m ,ro'a'ility o# o'servin% t+ese &e#e$ts is at a &istan$e o# 1 mm 'et=een $enters.

T+ere#ore =it+ $"tter o# t+i$ness 1.2C mm6 t+ese 'lans are $"t #rom t+e mi&&le. Ei%+t

&o"'le 'lans are loa&e& on a man&rel6 $overe& =it+ a,,ro,riate r"''er sleeve6 mat$+in%=it+ insi&e &iameter o# rin%. T+e $"tters are #itte& on anot+er man&rel =it+ a,,ro,riate

s,a$ers =it+ in t+e $"tter. T+e $"tter an& rin%s are rotate& in o,,osite &ire$tion. T+e re@"ire&

&e,t+ o# $"t is set an& t+e $"ttin% is ,er#orme&. T+ere are ; semi5a"tomati$ an& 1 *N*

s,littin% ma$+ines in rin% s+o,. !an,o=er is one ,er ma$+ine.

3- Turning an$ *oring

0"tsi&e t"rnin% an& insi&e 'orin% is a very im,ortant ,ro$ess. In t+is ,ro$ess t"rnin%

an& 'orin% are &one sim"ltaneo"sly. T+is ste, is o# maim"m im,ortan$e 'e$a"se a n"m'er

o# ,arameters are &e,en&ent on t+is o,eration. T+ese are:

!aor iameter

!inor iameter

Ra&ial T+i$ness

0val5ity

*lose& Ga, /a#ter %a, $"ttin%

>ree Ga, /a#ter %a, $"ttin%

Tan%ential t+i$ness

(i%+t ,assa%e

-is"al a,,earan$e

1


32/92

Rin%s in t+e #orm o# ,a$ets /


33/92

Pro*ess Flo( Chart &or Chro%e Plating

Ring0 1rom Fini0)

Ga4 +orner Sizing *9)ere3er

0 e(i:ed

Mandrel re4aration

Sand &la0ting

Mandrel 9a0)ing

Et()ing *9)ere3er re;uired,

a00i3ation *9)ere3er

Initial (oating *9)ere3er

+)rome lating


34/92

Pro*ess Flo( Chart &or Mol+ Plating

3

Mandrel .a0)ing

Stage in04e(tion

Neutralizing

Ring0 1rom Fini0)

ro:le Grinding

Outer Diameter

Mol2 S4ra2

Sand &la0ting

Fini0) Turning

A5ial .idt)

Mandrel

Deurring

La44ing,

Auto Ga4 Grinding

La In04e(tion


35/92

RI.G TERMI.OLOG8

A. RingLand: T+e ,art o# t+e ,iston 'et=een t+e rin% %rooves an& a'ove t+e to, rin% t+at $on#ines

an& s",,orts t+e ,iston rin%s.

). /eat Da%: A narro= %roove in t+e to, lan& "se& in some ,istons to +el, $ontrol +eat %ettin% to t+e

to, rin%. It a$t"ally #ills =it+ $ar'on in normal o,eration an& limits +eat #lo= to t+e rin%.

C#Co%pression /eight: T+e &istan$e #rom t+e ,in $enterline to t+e to, o# t+e ,iston.

D#Ring )elt: T+e area on t+e ,iston 'et=een t+e to, o# t+e ,in 'ore an& t+e to, o# t+e ,iston =+ere

t+e rin% %rooves are ma$+ine&.

E# Piston /ead: T+e to, area o# t+e ,iston =+ere $om'"stion %as ,ress"re is eerte&.

F# Piston Pin: Eit+er ,ress5#it or #loatin%6 t+e ,in $onne$ts t+e ro& to t+e ,iston =it+ 'earin% s"r#a$e.

4


36/92

G# S0irt: T+e ,art o# t+e ,iston 'elo= t+e rin% 'elt.

/# Ma4or Thrust Fa*e: T+e si&e o# t+e ,iston $arryin% t+e %reatest t+r"st loa&. (ooin% at t+e ,iston

#rom t+e #ront in an en%ine rotatin% $lo$=ise6 t+is is t+e le#t si&e.

I# Minor Thrust Fa*e: T+e si&e o# t+e ,iston o,,osite t+e maor t+r"st #a$e.

B# Piston Pin )ushing: I# "se&6 t+e '"s+in% 'et=een t+e ,istons ,in 'ore an& t+e ,in.

.#S*u&& )and: 0ne or more raise& 'an&s o# ,iston material "se& in some ,iston &esi%ns to re&"$e

s$"##in%.

5


37/92

O# Groo7e Depth: T+e &istan$e 'et=een t+e 'a$ o# t+e rin% %roove an& t+e $ylin&er =all =it+ t+e

,iston $entere&.

P# Groo7e Root Dia%eter: Piston &iameter meas"re& at t+e 'a$ o# t+e %roove. !ay vary on t+e same

,iston 'et=een rin% %rooves.

@# Land Dia%eter: iameter o# a %iven lan&. *an sometimes vary 'y &esi%n #rom to, to 'ottom.

R# Land *learan*e: T+e &i##eren$e in &iameter 'et=een t+e $ylin&er 'ore an& t+e lan& &iameter.R is

1)2 t+e total.

S# S0irt Clearan*e: T+e &i##eren$e in &iameter 'et=een t+e $ylin&er 'ore an& sirt &iameter. S is

1)2 t+e total.

T# S0irt Groo7e: A rin% %roove $"t 'elo= t+e ,in 'ore to $arry an oil rin%.

U# Pin )ore O&&set: T+e &istan$e t+e ,in 'ore is o##set #rom $enter.

?# Groo7e Spa*er, Use& on re,rove& ,istons to ret"rn a rin% %roove to s,e$s or in some ,er#orman$ea,,li$ations to #a$ilitate t+e "se o# narro=er rin% sets t+an t+e %rooves =ere ori%inally $"t #or.

6


38/92

RI.G TERMS MEASUREME.TS

A# Free gap: T+e rin% en& $learan$e =+en t+e rin% is "n$om,resse&.

)# Co%pressed gap: Also no=n as rin% %a,6 it is t+e en& %a, meas"re& =+en t+e rin% is installe&.

C# Radial 5all Thi*0ness: t+e &istan$e 'et=een t+e insi&e an& o"tsi&e #a$es o# t+e rin% =all.

D# Ring Dia%eter: !eas"re& =it+ t+e rin% installe&.

E# Inside Dia%eter: !eas"re& =it+ t+e rin% installe&.

F# Ring Sides,T+e to, an& 'ottom s"r#a$es o# t+e rin%.

G# Ring Fa*e: T+e ,art o# t+e rin% in $onta$t =it+ t+e $ylin&er =all.

/# Side Clearan*e: *learan$e 'et=een t+e rin% %roove an& t+e rin%.

I# Ring 5idth: It is t+e aial =i&t+ o# t+e rin%.

B# Torsional T(ist: A '"ilt5in im'alan$e 'et=een t+e =ay t+e ",,er an& lo=er si&es $om,ress t+at

$a"ses a t=ist in t+e rin% =+en $om,resse&. Use& to sea 'ot+ t+e rin% in t+e %roove an& t+e rin% to

t+e $ylin&er =all.

7


39/92

MA.UFACTURI.G OPERATIO.S

I.SIDE C/AMFERI.G: T+e %oo& a#ter t+e t=o ty,es o# ins,e$tion are t+en ,asse&

t+ro"%+ t+e ,ro$ess o# insi&e $+am#erin% in =+i$+ t+e inner si&es o# t+e rin%s are $+am#ere&

a$$or&in% to t+e &esire& an%le.

OUTSIDE C/AMFERI.G MAC/I.E: T+e %oo& a#ter t+e t=o ty,es o# ins,e$tion are

t+en ,asse& t+ro"%+ t+e ,ro$ess o# o"tsi&e $+am#erin% in =+i$+ t+e o"ter si&es o# t+e rin%s

are $+am#ere& a$$or&in% to t+e &esire& an%le.

STAMPI.G,In t+is ,ro$ess t+e rin%s are %iven stam,s o# t+e $om,any on t+e si&es o# t+e

rin%s lie G0E.

GROO?I.G,T+e ,ro$ess o# %roovin% is &one a#ter stam,in%. T+is ,ro$ess is $arrie& o"t

only #or t+e oil ,iston rin%s an& not #or t+e $om,ression rin%s. In t+is ,ro$ess #irstly t+e rin%s

are $lose& =it+ t+e +el, o# $om,resse& airs ,ress"re =+i$+ is "se& to $lose t+eir %a,s so t+at

=+ile t+e ,ro$ess o# %roovin% t+e %roovin% tool s+o"l& not inter#ere =it+ t+e %a,. T+e tool

"se& #or %roovin% is a m"lti5tool =+i$+ is "se& to save t+e time.

SLOTTI.G,T+e %roovin% ,ro$ess is #ollo=e& 'y slottin%. In t+e ,ro$ess t+e rin%s are a%ain

,a$e& $lose& 'y t+e $om,resse& air ,ress"re to remove t+e %a,s an& a man&rel is #orme&

=+i$+ is t+en ,la$e& 'et=een t+e +ea&sto$ an& tailsto$. Here t+e rin%s remain stationary

=+ile t+e slottin% tool rotates an& maes a slot in t+e rin%s6 =+en one slot is $om,lete& t+e

,a$ o# rin%s is rotate& #or ot+er slot6 t+is all is a"tomati$ ,ro$ess. T+e tool "se& +ere is also a

m"lti tool an& t+is ,ro$ess is assorte& o# millin% ,ro$ess. ot+ t+e a'ove sai& ,ro$esses vi4.

%roovin% an& slottin% are &one only #or 0il $ontrol rin%s.

FI.IS/ TUR.I.G: T+is ,ro$ess is same as a'ove i.e. t+e man&rel #ormation is &one in t+e

same manner as in t+e a'ove sai& ,ro$ess. T+e &i##eren$e is only #or t+e ty,e o# tool "se& t+at

is t+e tool "se& +ere is t"rnin% tool "se& #or #inis+ t"rnin%. T+e man&rel o# rin%s is rotate&

@


40/92

GAP SII.G,T+e #ollo=in% ,ro$e&"re to t+e #inis+ t"rnin% is %a, si4in%6 as t+e name

in&i$ates in t+is ,ro$ess t+e %a, o# t+e rin%s is ma&e a$$or&in% to t+e &esire. In t+is ,ro$e&"re

a $"tter +avin% teet+s on its s"r#a$e is rotate& an& t+e rin%s are ,"s+e& =it+ t+e +el, o# a ram

a%ainst it an& t+e %a, is ma&e o# t+e re@"ire& si4e.

)E?ELLI.G,T+is ,ro$ess is $arrie& o"t #or t+e oil $ontrol rin%s an& is also no=n as

insi&e $+am#erin% or o"tsi&e $+am#erin%. Here in t+e $+"$ a &ie is #ie& s"ita'le to t+e rin%

si4e an& sin%le rin% is e,t insi&e t+e &ie =+i$+ is rotatin% no= an& =it+ t+e +el, o# a

stationary tool t+e ,ro$ess is ,ro$ee&e&.

I.SIDE GROO?I.G: T+is ,ro$ess is very so,+isti$ate& so it is $arrie& o"t on t+e *N*

ma$+ine in =+i$+ a '"n$+ o# rin%s is ,la$e& in a &ie6 s"ita'le to t+e si4e o# rin%s6 an& is

rotate&. T+"s t+e ,ro$ess is $arrie& o"t an& insi&e %roovin% is &one.

.OTC/ MILLI.G: T+is ,ro$ess is &one #or t+e $om,ression rin%s in =+i$+ a semi$ir$"larnot$+ is ma&e =it+ t+e +el, o# a #a$e $"tter. T+is ,ro$ess is &one #or ea$+ an& every rin%.

LAPPI.G: T+e la,,in% o,eration is on t+e aial =i&t+ o# t+e rin%. T+e t=o %rin&in% =+eels are

o,erate& at a @"ite +i%+ s,ee&. T+e ",,er %rin&in% =+eel is li#te& an& t+e rin%s are "nloa&e&.

3A


41/92

?ARIOUS MAC/I.ES USED I. T/E RI.G S/OP

>ollo=in% are t+e &etaile& &es$ri,tion o# vario"s ma$+ines "se& in

man"#a$t"rin% o,erations o# t+e ,ro$esses involve& in main% a ,iston rin%

a#ter t+ey $ome #rom Rin% #o"n&ry.

1# ROUG/ GRI.DI.G SECTIO.

Rin%s o'taine& #rom #o"n&ry +ave ,oor s"r#a$e #inis+ an& less &imensional a$$"ra$y. Rin%

'lans are %rin&e& aially to a$+ieve t+e &imensions re@"ire&. To %rin& rin%s aially $enter5less

%rin&in% ma$+ines are "se&. T+ese are very ro'"st6 ri%i&6 +eavy ma$+ines. In t+is ,ro$ess rin% 'lans

are #e& t+ro"%+ a ma%neti$ #ee&er to t+e t=o revolvin% %rin&in% =+eels6 se,arate& 'y a &istan$e =+i$+

is e@"al to t+e t+i$ness o# t+e rin% re@"ire&.

Aial =i&t+ %rin&in% is $arrie& o"t in t=o or t+ree sta%es as ,er re@"irement an& &i##erent

s,e$ial ,"r,oseO &e&i$ate& $entreless %rin&ers are "se& #or %rin&in% t+e rin% 'lans to a$+ieve re@"ire&si4e as ,er ,ro$ess s+eet.

MAC/I.E MA6E GRI.DI.G STAGE .UM)ER

ES( Ro"%+)!e&i"m Grin&in% C

H!T Ro"%+)!e&i"m Grin&in% 2

AE>IG !e&i"m)>inis+ %rin&in% 1

>S >inis+ %rin&in% 1

31


42/92

)esle+/MT Rough grinding Ma*hine,-

Use& #or ro"%+)me&i"m %rin&in% o# aial =i&t+ o# rin%s.

Borin% ,rin$i,le is $entre less %rin&in% =it+ +ori4ontal s,in&les.

Parameter $ontrolle& is aial =i&t+ o# rin%.

!an,o=er 2 ,ersons ,er s+i#t.

An%le 'et=een %rin&in% =+eels


43/92

DFS &inish Grinding Ma*hine ,-

Use& #or #inis+ %rin&in% o# aial =i&t+ o# rin%s.

Borin% ,rin$i,le is $entre less %rin&in%.

Parameter to 'e $ontrolle& is aial =i&t+ o# rin%s.

!an,o=er 2 ,ersons ,er s+i#t.

An%le 'et=een %rin&in% =+eels5


44/92

s+i#t an& en& o# ,ro&"$tion.

Splitting,-

33


45/92

It is t+e o,eration o# $"ttin% a sin%le Lo"'le lanM into t=o sin%le 'lans. T+is o,eration is

not $arrie& o"t on all ty,es o# rin%s. Us"ally t+is o,eration is $arrie& on -1 rin%s. -1 rin%s are

+ar&est o# all t+e materials "se& #or rin% man"#a$t"rin% an& it is "s"ally $ast in &o"'le 'lans6 #rom a

sin%le L&o"'le 'lanM6 t=o rin%s $an 'e o'taine&.

-1 $om,osition is s"$+ t+at &"rin% $astin% maim"m metall"r%i$al an& $astin% &e#e$ts lie

sla% in$l"sion6 'lo= +oles an& ,orosity lie in t+e mi&&le o# t+e rin%. T+e maim"m ,ro'a'ility o#

o'servin% t+ese &e#e$ts is at a &istan$e o# 1 mm 'et=een $enters. T+ere#ore =it+ $"tter o# t+i$ness

1.2C mm6 t+ese 'lans are $"t #rom t+e mi&&le. Ei%+t &o"'le 'lans are loa&e& on a man&rel6 $overe&

=it+ a,,ro,riate r"''er sleeve6 mat$+in% =it+ insi&e &iameter o# rin%. T+e $"tters are #itte& on

anot+er man&rel =it+ a,,ro,riate s,a$ers =it+ in t+e $"tter. T+e $"tter an& rin%s are rotate& in

o,,osite &ire$tion. T+e re@"ire& &e,t+ o# $"t is set an& t+e $"ttin% is ,er#orme&. T+ere are ; semi5

a"tomati$ an& 1 *N* s,littin% ma$+ines in rin% s+o,. !an,o=er is one ,er ma$+ine.

2# DOU)LE CAM TUR.I.G !Turning and )oring",-

0"tsi&e t"rnin% an& insi&e 'orin% is a very im,ortant ,ro$ess. In t+is ,ro$ess t"rnin% an&

'orin% are &one sim"ltaneo"sly. T+is ste, is o# maim"m im,ortan$e 'e$a"se a n"m'er o# ,arameters

are &e,en&ent on t+is o,eration. T+ese are:

!aor iameter

!inor iameter

Ra&ial T+i$ness

0vality

*lose& Ga, /a#ter %a, $"ttin%

>ree Ga, /a#ter %a, $"ttin%

Tan%ential t+i$ness

(i%+t ,assa%e test

-is"al a,,earan$e

Rin%s in t+e #orm o# ,a$ets /


46/92

internal $"ttin% an& t+ree on tool ,ost #or eternal t"rnin%. T+e "sa%e o# t+ree tools in sin%le ,ass

allo=s savin% o# time an& %oo& res"lts. Sele$tion o# $am to s"it t+e ovality o# rin%s is mentione& on

,ro$ess s+eet.

!a$+ines "se& #or t"rnin% an& 'orin% are name& as *T /o"'le *am T"rnin% ma$+ines.T+ese are 1C in n"m'er in t+e rin% ma$+ine s+o,. T+ese ma$+ines are semi5a"tomati$. 0ne o,erator

is em,loye& #or ea$+ ma$+ine.

A#ter t"rnin% an& 'orin% t+e rin% is $lam,e& on $arrier an& remove& #rom ma$+ine s,in&les

'y releasin% t+e air ,ress"re an& move& to %a, $"ttin% ma$+ine.

3# GAP CUTTI.G ,-

35


47/92

Ga, $"ttin% o,eration is ,er#orme& on t+e same station as o# t"rnin% an& 'orin%. It is a semi5

a"tomati$ ma$+ine. In %a,5$"ttin%6 t+e rin%s are +el& ,ne"mati$ally in %a,5$"ttin% ma$+ine an& a

millin% $"tter is "se& to $"t t+e %a, in t=o ,asses.

In #irst ,ass6 one en& o# %a, is $"t =it+ a rotatin% $"tter an& t+e $"tter is t+en move& 'a$=ar&s. T+e

ot+er en& o# t+e %a, is t+en ali%ne& =it+ t+e $"tter6 an& t+is ste, is a ,art o# t+e a"tomati$ $y$le o# t+e

ma$+ine. T+e $"tter t+en $"ts t+e ot+er en& an& t+e %a, is $"t in all rin%s in a ,a$et. *"tter t+en

moves 'a$=ar&s an& all t+e rin%s are "nloa&e& #rom t+e ma$+ine man"ally 'y releasin% air ,ress"re.

9# AIAL 5IDT/ I.SPECTIO. ,-

T+is ma$+ine is 'asi$ally an ins,e$tion ma$+ine. Rin% is loa&e& #rom one si&e an& in an

arran%ement =+i$+ ,"s+es t+e rin% one 'y one "n&er an aial =i&t+ $+e$in% instr"ment. T+en t+is

arran%ement se,arates o"t t+e %oo&6 over5si4e6 "n&er5si4e rin%s. T+"s all t+ese $ate%ories o# rin%s

are $olle$te& se,arately.

:# STAMPI.G MAC/I.E ,-

T+is ma$+ine ,"ts a stam, on t+e rin%s o# t+e $om,any lie G0E. T+is +as t+e same loa&in%

an& "nloa&in% arran%ement as t+at o# t+e aial5=i&t+ ma$+ine.

;# FI.IS/ TUR.I.G MAC/I.E ,-

36


48/92

e#ore t+is only t+e *T ma$+ine &oes t+e o"tsi&e t"rnin% o,eration i.e.6 re&"$in% t+e

ra&ial t+i$ness o# t+e rin%. T+is %ives t+e #inis+in% to"$+ to t+e rin% #rom o"tsi&e. Rin%s in

t+e #orm o# ,a$ets /


49/92

Ga, $"ttin% o,eration is ,er#orme& a#ter #inis+ t"rnin%. In %a,5$"ttin% t+e rin%s are

+el& lie t+e o,erations o# aial =i&t+ an& stam,in% ma$+ines. T+is is t+e only o,eration a#ter

%a, $"ttin% it %ives t+e #inis+in% to"$+ to t+e %a,. In t+is ,ro$e&"re a $"tter +avin% teet+s on

its s"r#a$e is rotate& an& t+e rin%s are ,"s+e& =it+ t+e +el, o# a ram a%ainst it an& t+e %a, is

ma&e o# t+e re@"ire& si4e. T+e loa&in% an& "nloa&in% are same as t+e aial =i&t+ an&

stam,in% ma$+ines.

=# COIL 5I.DI.G MAC/I.E ,-

In t+is ma$+ine a $oil is #orme& =+i$+ is $om,resse& in a man&rel. It is "se& #or t=o

&iameters i.e.6 8


50/92

T+e %roovin% ,ro$ess is #ollo=e& 'y slottin%. In t+e ,ro$ess t+e rin%s are a%ain

,a$e& $lose& 'y t+e $om,resse& air ,ress"re to remove t+e %a,s an& a man&rel is #orme&

=+i$+ is t+en ,la$e& 'et=een t+e +ea&sto$ an& tailsto$. Here t+e rin%s remain stationary

=+ile t+e slottin% tool rotates an& maes a slot in t+e rin%s6 =+en one slot is $om,lete& t+e

,a$ o# rin%s is rotate& #or ot+er slot6 t+is all is a"tomati$ ,ro$ess. T+e tool "se& +ere is also a

m"lti tool an& t+is ,ro$ess is assorte& o# millin% ,ro$ess. ot+ t+e a'ove sai& ,ro$esses vi4.

%roovin% an& slottin% are &one only #or 0il $ontrol rin%s. T+e slots are in t+e #orm o# s.

T+ese ma$+ines are #o"r in n"m'er.

11# .OTC/ MILLI.G MAC/I.E ,-

T+is ,ro$ess is &one #or t+e $om,ression rin%s in =+i$+ a semi$ir$"lar not$+ is ma&e

=it+ t+e +el, o# a #a$e $"tter. T+is ,ro$ess is &one #or ea$+ an& every rin%. T+is is a small

ma$+ine an& is si in n"m'er in t+e rin% ma$+ine s+o,. T+e $"tter +as many teet+ an& t+ey

mill t+e not$+ in #or=ar& stroe. It +as one =orer on it. It is a li%+t ma$+ine. 0nly one rin%

is o,erate& at one time.

12#)E?ELLI.G MAC/I.E ,-

T+is ,ro$ess is $arrie& o"t #or t+e oil $ontrol rin%s an& is also no=n as insi&e

$+am#erin% or o"tsi&e $+am#erin%. Here in t+e $+"$ a &ie is #ie& s"ita'le to t+e rin% si4e

an& sin%le rin% is e,t insi&e t+e &ie =+i$+ is rotatin% no= an& =it+ t+e +el, o# a stationary

tool t+e ,ro$ess is ,ro$ee&e&

13# I.SIDE GROO?I.G MAC/I.E ,-

4A


51/92

T+is ,ro$ess is very so,+isti$ate& so it is $arrie& o"t on t+e *N* ma$+ine in =+i$+ a

'"n$+ o# rin%s is ,la$e& in a &ie6 s"ita'le to t+e si4e o# rin%s6 an& is rotate&. T+"s t+e ,ro$ess

is $arrie& o"t an& insi&e %roovin% is &one. T+is +as very less =orin% in t+e in a mont+.

19# I.SIDE C/AMFERI.G MAC/I.E ,-

T+e %oo& a#ter t+e t=o ty,es o# ins,e$tion are t+en ,asse& t+ro"%+ t+e ,ro$ess o#

insi&e $+am#erin% in =+i$+ t+e inner si&es o# t+e rin%s are $+am#ere& a$$or&in% to t+e &esire&

an%le.

1:# LAPPI.G MAC/I.E ,-

T+e la,,in% ma$+ine &oes t+e o,eration on t+e aial =i&t+ o# t+e rin%. It o,erates 2C rin%s in

a %o. T+e t=o %rin&in% =+eels are o,erate& at a @"ite +i%+ s,ee&. T+e ",,er %rin&in% =+eel is li#te&

an& t+e rin%s are "nloa&e&. It "ses $"ttin% oil =+i$+ is also terme& as $oolant as erosene oil. 0ne

=orer o,erates on it at one time. An& t+ese are si in n"m'er in t+e rin% ma$+ine s+o,. (a,,in%

o,eration is a s",er #inis+in% o,eration. It is &one =it+ t+e +el, o# ma$+ine name& HE((ER5HRAU(I*. T+e ma$+ines $onsists o# +ea& rotatin% in o,,osite &ire$tions. ot+ t+ese +ea&s +ave

la,,in% stones atta$+e& to t+em. T+e aial =i&t+ is $ontrolle& 'y varyin% t+e ,ress"re o# ",,er +ea&

an& amo"nt o# erosene s",,ly. !etal removal rate $an 'e in$rease& or &e$rease&. T+e timer is also

atta$+e& to t+e ma$+ine #or timin% t+e ,ro$ess &e,en&in% ",on t+e si4e o# $"t.

1;# /O.I.G MAC/I.E ,-

T+is ma$+ine &oes t+e #inis+in% o,eration on t+e rin%s '"t t+e material removal is t+e smallest

#rom all ot+er o,erations in t+e rin% ma$+ine s+o,. T+e rin%s are ,la$e& in a ,a$et o# 1C52

&e,en&in% on t+e si4e. T+ere a'o"t siteen +onin% ma$+ines in t+e rin% ma$+ine s+o,. Honin%

ma$+ine is anot+er s",er #inis+in% o,eration an& also to ,rovi&e %oo& #inis+. It is &one a#ter #irst

la,,in%. In t+is ,ro$ess t+e o"ter s"r#a$e o# t+e rin%s is ,olis+e&. T+e set o# rin%s are #ie& on a tool

an& t+e tool is atta$+e& =it+ a +y&ra"li$ ram6 =+i$+ moves ", an& &o=n sim"ltaneo"sly revolves. T+e

tool re$i,ro$ates an& revolves in a sleeve. "rin% +onin% 6 a mit"re o# aerolite mo'ile oil an& sl"rryo# sili$on $ar'i&e is $ir$"late& t+ro"%+ rin%s6 =+i$+ $reates a s+iny a,,earan$e on s"r#a$e o# rin%s.

41


52/92

T+e stroe o# t+e ram &e,en&s on t+e n"m'er o# rin%s atta$+e& to tool. T+e rotation o# ram $an 'e

in$rease& or &e$rease& a$$or&in% to t+e ty,e o# t+e rin%. T+e time o,eration varies #rom rin% to rin%

a$$or&in% to t+e material o# t+e rin%. T+ere are %rooves ,rovi&e& in t+e sleeves as to allo= oil to rea$+

t+e 'ottom o# sleeve a#ter rin%s are ,resse& in it. A#ter sometimes t+e sleeve =ears o"t an& it is t+en

re,la$e& 'y ne= sleeve. A#ter +onin% t+e rin%s are =as+e& 'y aerolite oil an& $+e$e& #or s"r#a$e

#inis+6 ree$te& rin%s are re5+one&.

42


53/92

1


54/92

one. T+is is a one man o,erate& ma$+ine. It 'asi$ally re&"$es t+e aial =i&t+ o# t+e rin%. It is "s"ally

#or 'i%%er rin%.

2# OUTSIDE C/AMFERI.G MAC/I.E ,-

T+e %oo& a#ter t+e t=o ty,es o# ins,e$tion are t+en ,asse& t+ro"%+ t+e ,ro$ess o#

o"tsi&e $+am#erin% in =+i$+ t+e o"ter si&es o# t+e rin%s are $+am#ere& a$$or&in% to t+e

&esire& an%le.

21# OS EDGE )REA6I.G MAC/I.E ,-

T+ese ma$+ines are "se& to 'rea t+e o"tsi&e e&%es an& mae t+e rin% ta,er in s+a,e

#rom 'ot+ t+e o"ter ,eri,+ery e&%es.

22# PROFILE GRI.DER ,-

Pro#ile %rin&in% is &one on moly'&en"m $oate& rin%s. T+e rin%s a#ter moly $oatin% #irst sent

#or 0.. %rin&in%. It is &one on a *N* ,ro#ile %rin&er. In t+is o,eration a s,e$ial $onto"r is %rin&in%

on t+e set o# rin%s mo"nte& on t+e s,in&le o# t+e ma$+ine. T+e rin%s in t+e %rin&in% =+eel rotate in

t+e same &ire$tion. T+e %rin&in% =+eel +as t+e same $onto"r as is re@"ire& on t+e rin%s. A#ter every

$y$le t+e =+eel is &resse& =it+ &resser6 =+i$+ +as t+e same ,ro#ile as t+at o# =+eel. T+e rin%s are$+e$e& #or o"t o# $entre 'y a +ori4ontalO sleeve t+at ,resses t+e rin%s in t+e $entre. Pro#ile %rin&in% is

'asi$ally &one to se,arate t+e sta$ o# rin%s 'e$a"se i# t+e rin%s are se,arate& man"ally t+e only layer

$an 'e $+i,,e& o##6 as it is 'rittle in nat"re.

43


55/92

23# TRI-)AT/ 5AS/I.G,-

T+e tri 'at+ =as+in% is &one in a t"' =+i$+ $ontains a$i&. T+e rin%s are ,"t in t+e try 'at+ #or

a ,arti$"lar time. T+e rin%s are t+en &rie& #or sometime an& s"'e$te& to #"rt+er ,ro$esses.

44


56/92

45


57/92

46


58/92

PISTO. RI.GS MAC/I.E S/OP

PROBECT,-

A. S$ra, Re&"$tion in moly $oate& -1 !aterial Piston Rin%s. TP!/Total Pro&"$tive !aintenan$e*. NP* st"&y/National Pro&"$tivity *o"n$il or Bor !eas"rement

S*rap Redu*tion in %ol+ *oated 6?1 Material

Piston Rings,-!0(*0ATING:5

47


59/92

!oly is &e#ine in t+e #lame s,rayin% ,ro$ess in =+i$+ moly is #e& in t+e #orm o# s,ray =ire

=it+ t+e +el, o# s,ray %"n =+ere it melte& 'y a #lamma'le %as =it+ t+e +el, o# oy%en an&

a$etylene. It +as a very +i%+ s$o##in% /oil o'servation ,ro,erties. It +as sel#5l"'ri$atin%

,ro,erty.

A&vanta%e:51. T+e layer o# !oly'&en"m %ives ve+i$le an& ma$+ine $om,onent t+at are e,ose& to

+i%+ me$+ani$al loa& an& %oo& sli&in% ,ro,erties6 $o",le& =it+ e$ellent =ear

resistan$e.2. It +as very +i%+ oil $om,ati'ility.

Pro4e*t Charter,-

)usiness *ase >rom Jan5e$ 21< 1C.7 avera%e ma$+inin% s$ra, in !0( *0ATE -1

Rin%s.

T+is +i%+er s$ra, lea&s to ,oor &elivery ,er#orman$e.

Pro$le% O$4e*ti7e

To re&"$e t+e s$ra, o# moly $oate& rin% in -1 material #rom 1C.7 to 1;.1 'y

E* 21;.

S*ope

Initial im,rovement =ill 'e &one on In&i$a moly $oate& rin%s t+e #in&in% =ill 'e

+ori4ontally &e,loye&

Resour*e Esti%ate No nee& o# any $a,ital investment at t+is ,oint

T8PES OF SCRAP,-

4@


60/92

PROCESS MAPPI.G

5A

;I!G 8I%H

&B%;"

M"%&;I"$

;I!G 8I%H

8I%H+%

!%>H

&DG&';&"-"G&

M$C

>"%&D

';&"-"G&

&DG&

';&"-"G&

M$C

>"%&D

';&"-"G&

;oughGrindin

g

nishGrinding D>% First)orosity

Gap

Grinding

Gap

Grindin

g

"xial

8idth

)role

Grindin

g

Grindin

g

Moly

>oating

Mandrel

)reparat

ion

Final Gap

Grinding'oring I:,

>hamfe

ringFinal

$a in'rushing

'arrel

Honning

Inspectio


61/92

FORMAT FOR DATA COLLECTIO. LOT TOTAL-

3:!I.DICA"

51


62/92

DATE OPERATIO. .AME @T8

!s*rap"

REMAR6S DETAIL

23


63/92

2


64/92

PROFILE GRI.DI.G J )REA6AGE OR

FI.S/I.G PROCESS

53

)G

';&"-"G

&

$oading of the

packet

Dresser

>ondition

ver

%ightness

fmandrel

,peed:Fe

ed

"xial widthvariation

'etween

packet

%oolin

g

'earing of

M:c

$ayer

.uality

Finishing: Dia* f

packet


65/92

Listing o& 6no(n Pro$le%

-ariation o'serve& in t+e &ia. o# ,a$et &"rin% in,"t at ,ro#ile %rin&in%.

Sleeve ali%nment =.r.t s,in&le.

Aial =i&t+ variation o'serve& at !)*.

-ali&ate t+e $a"ses in t+e A"% 0$t.

54

Material

Method Man

Machine


66/92

PROBECT- TPM !Total Produ*ti7e Maintenan*e"

TP! /Total Pro&"$tive !aintenan$e is &e#ine& as to o,eration to a$+ieve +i%+ e##i$ien$y

=it+ total em,loyee ,arti$i,ation t+ro"%+ TP! in sa#e =orin% environment =+i$+ maes "s

$om,etitive in '"siness 'y en+an$in% ,ro&"$tivity6 K"ality an& re&"$in% *ost.

DEFI.ITIO. OF TPM

5hat is TPMK

1. y esta'lis+in% a total system #or P! #or t+e entire li#e o# e@"i,ment.2. To set a %oal to maimise e@"i,ment e##i$ien$y /overall e##i$ien$y.


67/92

5h+ this %a*hine (as sele*ted

V 0l&est !)* =it+ lo= 0EE /9V Hi%+ 'rea &o=n #re@"en$y

V Hi%+ s$ra,V Hi%+ Set ", time 9.82

56

Dirt and 0ludge< oil

a((umulated and )ea32

(oolant lea/age on m=(


68/92

V (ast $riti$al o,eration e##orts o# ,revio"s o,erations =aste&

57


69/92

Fre'uen*+ o& Criti*al Parts

5@


70/92

5ho gets %ore $ene&ited $+ TPMK

)E.EFITS

6A

+USTOMERS

Em4lo2ee0

+OMAN>


71/92

V For e%plo+ees

(ess ,ress"re on maintenan$e #or "r%ent re,airs

(ess ,ress"re on ,ro&"$tion to re$over #rom 'rea&o=n losses

etter $oo,eration 'et=een maintenan$e6 ,ro&"$tion6 an& ot+er &e,artments

Re&"$e& $+an$e o# a$$i&ents

Hi%+er o' satis#a$tion

Im,rove& o' se$"rity

Im,rove& morale

Im,rove& team =orin%

etter =or environment

Im,rove& $omm"ni$ations

In$rease& sills t+ro"%+ a&&itional trainin%

0,erators !ore involvement in solvin% annoyin% e@"i,ment ,ro'lems

!aintenan$e !ore $+allen%in% =or

V For the *o%pan+

Hi%+er 0verall E@"i,ment E##e$tiveness

(ess L#ire#i%+tin%M to re,air ma$+ines

(o=er o,eratin% $osts

etter a'le to meet $ommitments to $"stomers.

.ATIO.AL PRODUCTI?IT8 COU.CIL STUD8 OR

5OR6 MEASUREME.T STUD8

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B0R !EASURE!ENT STU:5

5or0 %easure%entre#ers to a set o# &our te*hni'uest+at are $on$erne& =it+ t+e

eval"ation o# a tas in terms o# t+e time t+at s+o"l& 'e allo=e& #or an avera%e =orer

to ,er#orm t+at tas:/1 ire$t time st"&y6/2 Pre&etermine& motion time systems6/%IEI%I&,


73/92

B+ile o'servin% t+e =orer6 t+e time st"&y analyst eval"ates t+e =orers

,er#orman$e /,a$e6 an& a re$or& o# t+is ,a$e is atta$+e& to ea$+ =or element time.

T+is eval"ation o# t+e =orers ,a$e is $alle& ,er#orman$e ratin%. T+e o'serve& time is m"lti,lie& 'y t+e ,er#orman$e ratin% to o'tain t+e normal time

#or t+e element or t+e tas:

5or0 Measure%ent

Tas Hierar$+y levelBor !eas"rement

6

o9 level

%ask level8ork element'asic motion element level


74/92

Bor sam,lin%

ire$t time system

Pre&etermine& motion

Time

system

63


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So&t(are Training Report

COMPLETED AT

IDEAS DESIG. SOLUTIO.S !P" LTD#

Su$%itted in partial &ul&ill%ent o& the Re'uire%ent &or the a(ard o&

64


76/92

Degree o& )a*helor o& Te*hnolog+

In

Me*hani*al Engineering

Sumitted &2?-

!ame aspreet ,ingh

+niversity ;oll !o*1271216

SU&MITTED TO

DEARTMENT OF ME+!ANI+AL AND INDUSTRIAL

ENGG

&A&A &ANDA SING! &A!ADUR ENGINEERING

+OLLEGE

FATE!GAR! SA!I&

65


77/92

Solid9or/0?

66


78/92

,olid8orks is a D mechanical >"D computeraided design# program that runs

on Microsoft 8indows and is 9eing developed 9y Dassault,ystmes,olid8orks

>orp*( a su9sidiary of Dassault,ystmes( ,* "* EJliKy( France#* ,olid8orks is

currently used 9y over 2 million engineersorporation was founded in Decem9er 1@@ 9y Massachusetts

Institute of %echnology graduate on HirschtickL Hirschtick used 1 million he had

made while a mem9er of the MI% 'lack/ack %eam to set up the company*oncord(

Massachusetts( ,olid8orks released its rst product ,olid8orks @4( in 1@@4*

$atest solidworks 2A13software is released on cto9er( 6 ( 2A1*

Feature0 o1 0olid9or/0?

,olidworks can do the following things

1* D modeling*

2* &xceptional parts and assem9ly modeling

*2D Drawings

3* )owerful visualiKation and colla9oration

4* Design Ealidation and ,imulation

5* ,ustaina9ility Features

6* "nimation

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MA+!INE 7I+E

Introdu(tion?

Eices are used as holding device on machines like lathes( milling machine(

drilling machine etc* and also 9y tool makers for holding /o9s* Design wise

three types of vices are very common in use namely plain vice( swivel vice

and tool makers vice which is commonly known as 9ench vice*

A' lain 7i(e0

)lain vices 9olted directly on the Milling machine ta9le( is the most common

type of machine vice used for milling operations* %he vice may 9e fastened to

the ta9le with the /aws set either parallel or at right angles to the ta9le %slots*

8ork piece is clamped 9etween the xed and mova9le /aws*

&' S9i3el 7i(e

%he swivel vice is used to mill an angular surface in relation to a straight surface

without moving the work piece from the vice* In construction it may 9e

considered

as plain vice which is mounted on a particular 9ase graduated in degrees* %he

9ase

is clamped on the ta9le with the help of % 9olts*

+' Uni3er0al 7i(e

%he universal vice can 9e swiveled in a horiKontal plane like swivel vice

and can also 9e tilted in any vertical position for angular cuts* %he vice

not 9eing rigid in construction is mainly used in tool room work and hence

is called as tool makers universal vice*

6@


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Ma()ine 7i(e?

It consists of the following items

a# 'ase

9# Fixed /aws

c# aw plates or clamping plate

d# Mova9le /aws

e# ,crew and nut

f# ,crew rod

g# Handle

h# Handle cap

7A


81/92

@D modeling o1 4art0 o1 ma()ine 3i(e

!ome 0(reen o1 0olid9or/0?Home screen of the solid works looks like

>lick on the new le then on part modeling then following screen will pop up

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82/92

&a0e ?

,tep 1 First of all select plane according to re.uirement *

,tep 2 ,ketch on the plane according to re.uired view*

,tep +se the commands according to re.uirements like extrude(extrude cut

etc*

,tep 3 ,ave the 9ase model with name 9ase*

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83/92

'ase will 9e look like

Fi5ed a9?

Make the xed /aw according to dimensions 9y using re.uired commands and

save it with the name xed /aw* It remains xed to the 9ase of machine

vice*9/ects can 9e hold 9etween xed and mova9le /aw

It will 9e look like

7


84/92

Mo3ale a9?

pen the new le again and make the mova9le /aw according to the drawing and

then save it to with the name mova9le /aw which is xed in the handle side of

machine vice and used to hold the o9/ect with the help of xed /aw*

It will 9e look like

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85/92

+lam4ing 4late?

Make the clamping plate in the same way from drawing dimensions and then

save it with name clamping plate

>lamping plate model is shown 9elow

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86/92

!andle?

!ow make the handle of the machine wise and save it with the name handle*

Handle is used to rotate the screw rod so that mova9le /aw can move towards

the xed /aw*

Handle will look like

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87/92

S(re9 rod?

,imilarly make the model of screw rod and then save it* It has threads on it which

will help it to move forward and 9ackward according to re.uirements these are

meshed with threads inside the hole of 9ase*

,crew rod with threads on it shown 9elow

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88/92

!andle (a4?

Make the handle cap according to dimensions and save it with the name handle

cap* Handle caps are used on 9oth sides of handle so that handle will not fall

down from hole in screw rod*

Handle cap views are shown 9elow

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89/92

A00eml2 o1 ma()ine 3i(e 4art0?

"ssem9ly is the process of /oining the diNerent components of the o9/ects to

make re.uired o9/ect*

"ssem9ly involves the following steps

,tep 1 pen the new page and then select the assem9ly command*

7@


90/92

,tep 2 Insert or import the components of machine vice as shown 9elow

@A


91/92

,tep !ow using mate command mate the diNerent components in a se.uence

to get the nal machine vice*

"fter mating completed machine vice will look like

@1


92/92

"fter designing design in send to manufacturing department of the company*

Documents

Jaspreet Singhtraining File