INTRODUCTION

Federal-Mogul Corporation is a global manufacturer and supplier of power train

components and vehicle safety products. The companys 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-Moguls 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 worlds 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
SUVs
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 todays 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 customers 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 its 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 customers 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

1
st
(S): SORT
Clearly distinguish needed items and eliminate the later

2
nd
(S): SET IN ORDER
Arrange the necessary item in a proper order so that they can be easily picked up for use.

3
rd
(S): SHINE
Clean your workplace completely so that there is no dust anywhere.

4
rth
(S): STANDARIZE
Maintaining a high standard of housekeeping at all times.

5
th
(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 tables .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 (4
TH
YEAR)