Assignment Of Manufacturing Processes

Saad Ur Rehmaan BME-B3-65 Danish Jalil BME B3-20 Azhar Hussain BME-B3-`56 Submitted To : Mr Toqeer Anwer Sb

Assignment on Manufacturing process

Introduction
Manufacturing Process
Manufacturing is the production of goods for use or sale using labor and machines, tools, chemical and biological processing, or formulation. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in which raw materials are transformed into finished goods on a large scale. Such finished goods may be used for manufacturing other, more complex products, such as aircraft,

household or automobiles, or sold to wholesalers, who in turn sell them to retailers, who then sell

them to end users the "consumers. Manufacturing takes turns under all types of economic systems. In a free market economy

Aluminium Piston Introduction

Primary manufacturing activity of Cast & Alloys was manufacturing aluminum pistons. The company has the capability to manufacture pistons in the diameter range 40mm to 200mm irrespective of complexity, adhering to International Quality Standards. The company manufactures pistons for Automotive, Stationary Engines, and Compressors etc. The company has competency in manufacturing pitons having Steel Struts, Alfin Ring Carrier and Oil Cavity etc.

Aluminum Piston Manufacturing Process Short Notes on Making Process The Rod
The piston begins as a three meter, solid aluminum rod. The reason aluminum is used is that it's lightweight, rust-proof, and easy to cut. A saw then cuts the rod into smaller pieces called slugs.

The Punch
A punch press and dye are pre-heated while the slug moves through an oven, heating it to the same temperature as the punch press. The slug is then removed from the oven, and placed into the punch. The press applies 2,000 tons of pressure onto the slug, forging it into the basic shape of a piston. This process causes the piston to become so hot, that it needs an hour to

The Oven
After the forgings cool down, they go through an oven twice more. The first time is at a higher temperature, to strengthen the metal. The second time is at a lower temperature to stabilize it.

The Lathe
A lathe is then used to cut excess metal from the basic form of the piston, taking it closer to its finished shape. Then tiny holes are drilled in the sides, allowing oil to lubricate the piston when it's in use. The same lathe then impresses three rings into the top of the piston. These rings, or grooves, help the piston glide, and allow it to form an air-tight seal.

The Wrist Pin Holes

A large hole is then drilled through both sides of the piston. This is where the wrist pin will go, attaching the piston to the connecting rod.

The Milling Machine

A milling machine then shaves up to a couple of centimeters off of each side of the piston where the large holes were drilled for the wrist pin insertion. This is to reduce the overall weight of the piston. Another milling machine takes some more metal off of the area where the three rings were formed earlier, bringing the piston one step closer to its final form.

Finishing the Job

Another lathe shaves a few more millimeters off of the top, allowing the piston to expand when heat builds up inside of it. Then a machine engraves model and production information. A human worker then smoothes out the sharp edges of the piston created during production. The holes created for the wrist pin are then put through a machine which smoothes them, allowing the wrist pin to fit comfortably. Finally, the pistons sprayed by hot, deionizer water, removing any lubricant or oil gathered through the manufacturing process.

The Process Which Is Performed In Work Shop to Making Piston Incomming Raw Material
Aluminum Alloy in its various grades is procured from the secondary smelters, who alloy the primary aluminum ingots to specifications as per national and international standards. The vendors for aluminum 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 (Aluminum Alloys) are subject to Optical Emission Spectrometer Analysis to determine metallurgical contents of various alloying elements. Strict compliance to national and international standards of aluminum alloys is maintained prior to accepting the raw material.

Piston Foundry
Casting aluminum for todays Hi-Performance pistons is a demanding science. All castings are cast on Semi Automatic & Fully Automated die casting machine in multipart permanent steel molds. Melts are subject to modification, nucleation, degassing, etc. using FOSECO fluxes. Melt preparation varies from different alloys. Dies-Mold and molten aluminum 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. The company maintains following quality records: SPC Chart In-Process Inspection Format Operation sheet Format Control Plan Format Piston Drawing Die Core drawing

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.

Cost of making a Piston

Conclusion
All of ACL's performance orientated Race Series V8 pistons include some tricky design technology such as integrated oil drain back slots and a pressure balancer groove in the top ring land to help reduce ring land breakage, in the case of detonation. In the instance if building a mildly supercharged 5 litre V8, or pushing for 450hp out of a normally aspirated engine, the is probable little advantage in investing large sums of money in forged pistons, when a correctlytuned engine with either standard Eutectic items or modern design Hypereutectic (ACL Race Series or similar) pistons will give the same power output and reliability levels.