PROJECT REPORT

ON
MANUFACTURING OF PISTON
Submitted in partial fulfillment of the requirements for the award of

Bachelor of Technology
In
MECHANICAL ENGINEERING

BY

CH RAGHAVENDER GOUD 13405A0302

G SATHISH GOUD 13405A0303
M SATYANARAYANA 13405A0305
M VISHNU VARDHAN 13405A0313

Under the esteemed guidance of

Mr.ARVIND YADAV
Assistant professor

DEPARTMENT OF MECHANICAL ENGINEERING

DVR COLLEGE OF ENGINEERING & TECHNOLOGY
(AN ISO 9001:2008 CERTIFIED INSTITUTION)

AFFILIATED TO JNTUH, HYDERABAD

KASHIPUR, SANGAREDDY, MEDAK

 DEPARTMENT OF MECHANICAL ENGINEERING

DVR COLLEGE OF ENGINEERING & TECHNOLOGY

(AN ISO 9001:2008 CERTIFIED INSTITUTION)

CERTIFICATE
This is to certify that the Industry Oriented Mini project work entitled
“MANUFACTURING OF PISTON” is a benefited record of the work done by

CH RAGHAVENDER GOUD 13405A0302

G SATHISH GOUD 13405A0303
M SATYANARAYANA 13405A0305
M VISHNU VARDHAN 13405A0313

Submitted to the Department of Mechanical Engineering, DVR College Of engineering and

Technology, Kashipur (V), Kandi, Sangareddy, Medak Dist, in partial fulfillment of the
requirement of the award of degree of Bachelor of Technology.

This record has not been submitted to any other University / Institution for the award of any
degree/diploma.

Internal examiner Head of the department

Mr. Aravind yadav Mechanical engineering

Mr. K Sheshacharyulu.
 EXTERNAL EXAMINER

ACKNOWLEDGEMENT

A project work of this magnitude is not possible without the help of several people
directly or indirectly. It is with immense satisfaction that we present our practical experience in
the form of project report on “MANUFACTURING OF PISTON”

We wish to express our sincere thanks to Prof.RAM PRASAD, Principal, DVR College
of engineering and technology, for his constant encouragement in doing this project.

We also render our thanks to Mr. K SESHACHARYULU head of the department,

Department of mechanical engineering, for his valuable suggestions which helped us a lot in
completing the project.

I would like to thank my guide. Mr.ARVIND YADAV for taking keen interest in my
training and giving me a chance to carry out this project under his supervision and also for
providing all the required technical knowledge and support required for this project.

I would also like to thank all the members of production department of SAMKRG
PISTONS AND RINGS PVT Ltd. for giving me a helping hand in the course of this project.

We extend our thanks to our entire faculty of mechanical engineering department and all
those who have been directly and indirectly involved during the tenure of our project work.

CH RAGHAVENDER GOUD 13405A0302

G SATHISH GOUD 13405A0303
M SATYANARAYANA 13405A0305
M VISHNU VARDHAN 13405A0313
 ABSTRACT

Machining of aluminium alloy castings is a predominant operation in the process of

piston manufacturing. Machining which removes the excess material on casted piston is to fit the
dimensional accuracy, surface finish, as per desired requirement of specifications. Many
parameters like tool geometry, work piece properties and tool and work piece interface effects
the machining operation. Machine defects are to be resulted due to lack of inter-relation of above
parameter. In this content “WHITE BAND’’ is one of the machining defects observed on
OUTER DIAMETER (OD) surface of piston in FOD ( FINISHED OUTER DIAMETER )
turning operation in CNC machine.

A tool after finishing of 5000 number parts production “white band’’ problem is
identified on outer diameter piston with “ NATURAL DIAMOND TOOL’’ Many of parameter
are to be considered like speed, feed, depth of cut, tool and work piece alignment, tool geometric
parameters etc. Even though using CNC work station the problem is repeated in a particular
model with natural diamond tool. Although certain parameters like tool speed, feed, and depth of
tool / work piece alignment are computer numeric controlled (CNC) still the problem band is
repeated with poor surface finish. So, we concluded that the geometry of tool has to be analyzed
against roughness variation. We made certain no. of calculations on roughness (Rt) by changing
rake angle , cutting angles (Ce,Cs) found good surface finish on piston OD surface without
White band and also improve the tool life.
 INDEX

CONTENTS
CHAPTER 1

1.0 INTRODUCTION 1

1.1 PISTON HEAD & CROWN 1

1.2 PISTON BARREL 3

1.3 PISTON SKIRT 3

1.4 PISTON RINGS 4

1.5 PISTON PIN 5

CHAPTER 2

2.0 LITARETURE THEORY 6

2.1 DESIGN OF PISTON 6

2.2 DESIGN CONSIDERATION FOR PISTON 7

2.3 MAIN COMPONENTS OF PISTON 7

2.4 PISTON CROSS SECTION & HEADD SHAPE 8

2.5 MATERIAL FOR PISTON 11

2.6 ALLUMINIUM ALLOY 11

2.7 MANUFACTURING PROCESS 13

2.7.1 RAW MATERIAL 13

2.7.2 MELTING PROCEDURE FOR AL-SI ALLOY IN INDUCTION

FURNANCE 13

3.7.3 ADVANTAGES OF AL-SI ALLOY 15

2.7.4 DEGASSING 15

2.7.5 METAL TREATMENT 15

2.8 CASTING 17
 2.8.1 STEPS INVOLVEDD IN CASTING PROCESS 17

2.8.2 DIE CASTING PROCESS 17

2.8.3 ADVANTAGES OF METAL CASTING 18

2.8.4 CASTING DEFECTS 18

2.8.5 OPERATIONAL FLOW CHART 19

2.9 HEAT TREATMENT 20

2.9.1 HEAT TREATMENT OF AL-SI ALLOY 20

2.9.2 BENEFITS OF HEAT TREATMENT 20

2.10 MACHINING PROCESS 21

2.10.1 BOSS HOLE DRILLING 21

2.10.2 OPEN END BORING 22

2.10.3 ROUGH OUTER DIAMETER 23

2.10.4 SURFACE FINISHING GROOVING 24

2.10.5 CIRCLIP GROOVING 25

2.10.6 RING GROOVING 26

2.10.7 OIL HOLE DRILLING 27

2.10.8 FINISHING OUTER DIAMETER 28

CHAPTER 3

3.0 EXPERIMENTAL EORK 29

3.1 ALLOY PREPARATION 29

3.2 PROCEDURE FOR MELTING Al-Si ALLOYS IN INDUCTION FURNANCE

3.3 PROCEDURE FOR CASTING 30

3.4 PROCEDUR FOR HEAT TREATMENT 32

3.5 PROCEDURE FOR MACHINING PROCESS 33-40

3.6 INSPECTION 41
 3.6.1 DIMENSIONAL INSPECTION 41

3.6.2 CMM (CO-ORDINATE MEASURING MACHINE) 42

3.6.3 VISUAL INSPECTION 42

CHAPTER 4

4.0 CONCLUSION 43

CHAPTER 5

5.0 BIBLOGRAPHY 44