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This presentation discussing 1- introduction of automotive industry and its importance 2-Manafacturing of car parts inside engine , outside engine and chisel of cars 3- introduction of Engine working 4- Piston working , stresses applied on it , material which made from , forging operation and Die 5-Crankshaft working , stresses applied on it , material which made from , forging operation and Die 6- Connecting rod working , stresses applied on it , material which made from , forging operation and Die 7- Outside Engine as body 8- Body Function and its Safety 9- chassis function , stresses applied on it , materials which can be made from , manufacturing operation 10-Doors requriments , material which made from 11-Suspension system function , parts , their function , stresses applied on it and material which from and manufacturing operations of these parts
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Forming Applications in Automotive Industry
Group 6Under Supervision of: Dr.
Mohamed A. Daha
The Automotive Industry The Automotive industry is one of the largest
industries in the World
Trends compete every year for the most powerful, economic , beautiful in the market
And what define the winner is the manufacturing process behind the spinning wheels
24 December 2013
DiscussingManufacturing of Car parts
Engine
pistons
crankshaft
Connection rod
Body
chassis
doors
suspension system
Rims
Shock Absorber
The Engine An engine is a related group of parts assembled
in a specific order , it’s designed to convert thermal energy given off by burning the fuel into a useful form.
We will just discussSome of it’s components and how it’s manufactured
Piston A solid disk or cylinder that fits inside a hollow
cylinder, and moves under pressure It’s made from cast iron or aluminum alloy It’s should be wear resistance and can take very heavy impact loading
Made: (Forging) The piston begins as a, solid aluminum rod Then after it’s been cut as slug and preheated
the slug is placed into the punch. The press applies 2,000 tons of pressure onto the
slug, forging it into the basic shape of a piston.
Crank Shaft It’s main duty Is to convert the angular motion of
the connection rod to a rotary motion to the transmit the mechanical motion.
It’s made from carbon steel alloy and the carbon percentage vary on the application of the crank shaft in different engines
Made: (open Die Forging)
Then it’s heat treatment due to residual stresses gained from forging so we make annealing process to increase ductility and reduce residual stresses
Connection Rod It’s a rod that connects from it’s upper pin the
piston and from it’s down pins the crank shaft It’s convert the Reciprocating motion of the
piston to an angular motion to the crank shaft It’s made from aluminum alloy now days to
withstand the high repeated stress (high endurance limit).
Made : (Closed Die Forging & Blanking)
First we use forging (on different steps ) to increase the mechanical properties of the rod and it’s resistance to impacts .
Then use blanking to cut the material which are not needed (scrap)
Out From the Engine
Now let’s try to see how Sheet Metal Forming Convert
The Body It consist from frame and chassis which it’s main
function to support the construction on the vehicle and give safety to it’s equipments and passengers
Safety First
Now days it’s design from weaker and lighter material
Aluminum , Magnesium WHY!!!!!!!
Chassis Automotive chassis or automobile chassis helps
keep an automobile rigid, stiff and unbending. Auto chassis ensures low levels of noise and vibrations
Chassis It used to be steel, but corrosion attacked unless
a good coating is added , then aluminum is used adding to its alloys zinc and magnesium to increase hardness and toughness, then titanium is added to alloys, and sometimes fiberglass and carbon fibers is used
Made : (Step 1)Rolling Using pinch rolling (form rolling) processes to
produce the chassis metal pars.
Made :(Step 2) (Sheet Hydro Metal forming)
Doors It's made of sheets of carbon steel.
Then the machine divide the big coil into small plates
Doors
Using deep drawing processes we produce the outer door panel
Doors
• At the next step we assemble the door frame with the inner door panel.
• Then assemble the outer door panel with the inner door panel by pressing them.
Suspension System
we need a way or a system that can dumb vibrations and stress to it’s minimum limits as possible to ensure the comfort of the passengers and safety of the vehicle
24 December 2013 Group 6
Shock Absorver A shock absorber is basically an oil pump placed
between the frame of the car and the wheels. The upper mount of the shock connects to the frame (i.e., the sprung weight), while the lower mount connects to the axle,
24 December 2013 Group 6
How it’s made Step 1 :(Tube Rolling)• At the next step we use the tube rolling processes
to produce the cylindrical shape of the tube.
• Then using a huge welding wheel we close the tube
24 December 2013 Group 6
How it’s made step 2 :(Impact Extrusion)• Using impact extrusion we compress the end of
the tube in order to make the tube hold more oil.
• Then we assemble the valve with the cylinder.
24 December 2013 Group 6
The Metal Wheels (Rims) The rim is the "outer edge of a wheel, holding
the tire". It makes up the outer circular design of the wheel on which the inside edge of the tire is mounted on vehicles such as automobiles.
Made :(Hot Forging)
Hot Forging - Takes a billet and creates metal lines through volume distribution with a hot press
Conclusion
The Metal Forming Technology (Sheet , Bulk) is one of the core manufacturing technology that have big impact on the automotive industry and all automobile manufactures every year try to come up with the best forming method to improve their design
Questions ………………………. ?
About :
Forming Applications in Automotive Industry
Group :6
Under Supervision of: Dr. Mohamed A. Daha
Mohamed Mostafa Ahmed
Mohamed Ibrahim Ahmed
Mahmoud Khairy Abd-
Elsalam
Eman Abd-Elfatah Ahmed
Takla Nabil Sawires
Beshoy Raafat Naaem
Toka Mohamed El-Sayed
Khulod Abdullah
Saleh
Mohamed Samir
Mohamed
Emad El-din Abd el
hafeiz
Team Members
Thank you for your time