ijri-me-02-0011

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International Journal of Research and Innovation (IJRI)


MULTI CAVITY DIE PREPARATION, ANALYSIS AND MANUFACTURING PROCESS OF DIESEL ENGINE PISTON

Kola Nagarjuna1, Koyilakonda-Sumanth2, Godi Subba Rao3,

1 Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad, India2 Assistant professor,Department of Mechanical Engineering, HyderabadInstitute of Technology and Management, Hyderabad, India3 professor , Department of Mechanical Engineering, HyderabadInstituteOf Technology And Management,Hyderabad,India

*Corresponding Author:

Kola Nagarjuna Research Scholar, Department of Mechanical Engineering, Hyderabad Institute of Technology and Management, Hyderabad,India

Published: July 22, 2014Review Type: peer reviewedVolume: II, Issue : IV

Citation: Kola Nagarjuna, Research Scholar (2015) MULTI CAVITY DIE PREPARATION, ANALYSIS AND MANUFACTUR-ING PROCESS OF DIESEL ENGINE PISTON

INTRODUCTION TO PISTON

In every engine, piston plays an important role in working and producing results. Piston forms a guide and bearing for the small end of connecting rod and also transmits the force of explosion in the cylinder, to the crank shaft through connecting rod.The piston is the single, most active and very critical com-ponent of the automotive engine. The Piston is one of the most crucial, but very much behind-the-stage parts of the engine which does the critical work of passing on the energy derived from the combustion within the combus-tion chamber to the crankshaft. Simply said, it carries the force of explosion of the combustion process to the crankshaft.Apart from the critical job that it does above, there are certain other functions that a piston invariably does -- It forms a sort of a seal between the combustion chambers formed within the cylinders and the crankcase. The pis-tons do not let the high pressure mixture from the com-

bustion chambers over to the crankcase.

PISTON DESCRIPTION

Pistons move up and down in the cylinders which exerts a force on a fluid inside the cylinder. Pistons have rings which serve to keep the oil out of the combustion chamber and the fuel and air out of the oil. Most pistons fitted in a cylinder have piston rings. Usually there are two spring-compression rings that act as a seal between the piston and the cylinder wall, and one or more oil control ring s below the compression rings. The head of the piston can be flat, bulged or otherwise shaped. Pistons can be forged or cast. The shape of the piston is normally rounded but can be different. A special type of cast piston is the hyper-eutectic piston. The piston is an important component of a piston engine and of hydraulic pneumatic systems. Pis-ton heads form one wall of an expansion chamber inside the cylinder. The opposite wall, called the cylinder head, contains inlet and exhaust valves for gases. As the piston moves inside the cylinder, it transforms the energy from the expansion of a burning gas usually a mixture of petrol or diesel and air into mechanical power in the form of a reciprocating linear motion. From there the power is con-veyed through a connecting rod to a crankshaft, which transforms it into a rotary motion, which usually

Abstract

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. The piston transforms the energy of the expanding gasses into mechanical energy. The piston rides in the cylinder liner or sleeve. Pistons are commonly made of aluminum or cast iron alloys.

In our project a piston for 1300cc diesel engine car will be designed using empirical formulas for the material Cast Iron. A 2D drawing is created from the calculations. The piston is modeled from 2D drawing using CREO parametric (Pro/Engineer) software.

Validation of die will be done using structural and dynamic analysis done in Ansys.

Generally manufacturing process for pistons is casting. So we have to design a die tool for the piston manufactur-ing. Designing of casting tool die for four cavities will be done. Core and Cavity will be extracted and total die will be designed as per the standards. CNC program will be generated for both core and cavity. Modeling, core cavity extraction, die design and CNC program generation is done in CREO parametric (Pro/Engineer) software.

1401-1402

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Drives a gearbox through a clutch. Components of a typi-cal, four stroke cycle, DOHC piston engine. (E) Exhaust camshaft, (I) Intake camshaft, (S) Spark plug, (V) Valves, (P) Piston, (R) Connecting rod, (C) Crankshaft, (W) Water jacket for coolant flow.

Suzuki GS 150 R specificationsEngine type : air cooled 4-stroke SOHCBore stroke(mm)=5758.6Displacement =149.5CCMaximum power = 13.8bhp @8500rpmMaximum torque = 13.4Nm @ 6000 rpmCompression ratio =9.35/1

3D MODEL PREPARATION

SKETCHER

REVELOVED MODEL

SLOT CUTTING

INTRODUCTION TO CASTING

Casting is one of the oldest procedures done on metals. Many products are formed using this method. Here is an attempt to share the knowledge of casting.Casting is one of four types: sand casting, permanent

mold casting, plaster casting and Die casting. All these types of castings have their own advantages and disad-vantages. Depending on the properties of the product re-quited, one of the casting is selected.Sand Casting: Sand casting is the oldest casting of the above. This method of casting is in use since 1950.The texture of the product depends on the sand used for cast-ing. The end product is given smooth finishing at the end. Usually iron, steel, bronze, brass, aluminium, magnesi-um alloys which often include lead, tin, and zinc are used.

DIE CASTING

Die casting is a metal casting process that is character-ized by forcing molten metal under high pressure into a mold cavity, which is machined into two hardened tool steel dies. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

Volume of the component ;(v) =83406.96Projected area ;(a)=3569.66A1 (side wall) =1275.88Density of material ;26e-6+Mass No Of Cavities x=4 Total projected area =a*x =3569.66*4 A=14278.64Projected area of over flows and feed system Af=A *c/100 C=10% of A =142.78Over all projected area:- =A+a1+Af =14278.64+142.78+1275.88 =15697.3mm2

Specific injection pressure of aluminum for pressure DIA casting =8kgf/mm2Total force acting on die plates F=projected area *injection pressure =15697.3*8 =125578.4kg =125.57 Tons Considering factor of safety of *1.2 125.5784*1.2=150.69=151 TonsRequired clamping force >150 tons160 tons machine specifications Clamping force =160 tonsDie stroke =380mmDie - height =200-550mmPlate size =675*680Injection stroke (L)=340Plunger die =50,60,65mmShot wt =1.3,1.8,2.1FILL TIME :- 0.092(582-516+(0.3*4.8))8.93/(516-100) =0.092(66+(1.44))8.923/416 =0.092*67.44*8.93/416 =55.40/416 =0.133sec =133 kg sec

MANUFACTURING (MOLD EXTRACTION)

A die is usually made in two halves and when closed it forms a cavity similar to the casting desired. One half of the die that remains stationary is known as cover die and the other movable half is called ejector die.

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Molds separate into at least two halves (called the core and the cavity) to permit the part to be extracted. In gen-eral the shape of a part must not cause it to be locked into the mold. For example, sides of objects typically cannot be parallel with the direction of draw (the direction in which the core and cavity separate from each other). They are angled slightly (draft), and examination of most plastic household objects will reveal this. Parts that are "bucket-like" tend to shrink onto the core while cooling, and after the cavity is pulled away. Pins are the most popular meth-od of removal from the core, but air ejection, and strip-per plates can also be used depending on the application. Most ejection plates are found on the moving half of the tool, but they can be placed on the fixed half. Core: The core which is the male portion of the mold forms the internal shape of the molding.Cavity: The cavity which is the female portion of the mold, gives the molding its external form.Shrinkage allowance considered as 1.3% for aluminum and the mould draft considered as 1.

CORE & CAVITY PREPARATION OF MODEL

PARTING SURFACE

CAVITY

CORE

CASTING TOOL DESIGN FOR MULTY CAVITY PISTON

EXPLODED VIEW

STRUCTURAL ANALYSIS ON MULTI CAVITY PISTON DIE

The above image shows imported model

The above image shows meshed model

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The above image shows load applied

The above image shows total deformation

The above image shows stress

INTRODUCTION TO MANUFACTURING

The manufacturing of various products is done at differ-ent scales ranging from humble domestic production of say candlesticks to the manufacturing of huge machines including ships, aeroplanes and so forth. The word manu-facturing technology is mainly used for the latter range of the spectrum of manufacturing, and refers to the com-mercial industrial production of goods for sale and con-sumption with the help of gadgets and advanced machine

tools. Industrial production lines involve changing the shape, form and/or composition of the initial products known as raw materials into products fit for final use known as finished products.

PROCEDURE OF MANUFACTURING

CAVITY ROUGHING

CUTTING TOOL

VERICUT

ROUGHING PROGRAM

%G71O0001(D:\nsr\roughing.ncl.1)N0010T1M06S5000M03G00X5.Y-5.G43Z0.H01G01Z-5.F200.X201.177Y-9.914X5.Y-14.828X201.177

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Y-19.742X5.Y-24.656X201.177Y-29.57X5.Y-34.484X201.177Y-39.398X5.Y-44.313

RESULTS TAbLE

STRUCTURAL ANALYSIS

Existing Model Modified Model

Total deformation 0.010822 0.0090683

Stress 37.317 31.116

Strain 0.00034214 0.00028758

FATIGUE ANALYSIS

Existing Model Modified Model

LIFE 1e6 1e6

Damage 1000 1000

Safety factor 2.3099 2.7703

Biaxiality indica-tion

0.98181 0.99333

Alternating stress 37.317 31.116

GRAPhS

CONCLUSION:

This project work deals with Multy cavity die preparation and manufacturing process of diesel engine piston".In the first step data collection and inputs are collected for the design of piston for diesel engine.In the next step design calculations are done using math-ematical formulaes from the calculations piston dimen-sions are required.A 3d model was generated using above calculations. Tool design calculations are done to prepare the die as-sembly.Core and cavity inserts are prepared using manufactur-ing model in pro- engineer.Mould tool parts are prepared and assembled withdrew set.Structural and Fatigue Analysis is conducted on mold to find structural and Fatigue behavior to, modifications done for core & cavity models to increase strength by add-ing stress relief holes.CNC program was generated for both core and cavity in-serts.

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By observing above information it concludes that using above process piston manufacturing can be done with multy cavities so it increases the production rate which in terms effects on reduction of cost of part production.

REFERENCES

1.Thermal analysis and optimization of i.C. Engine piston using finite element method

2.Design and analysis of i.C. Engine piston and piston-ring using catia and ansys software

3.Design analysis and optimization of piston using catia and ansys

4.Simulation of thermal-mechanical strength for marine engine piston using fea

5.Thermal analysis and optimization of i.C. Engine piston using finite element method

6.Modeling and analysis of diesel engine piston

7.Modeling, analysis and optimization of diesel engine piston

8.Thermal analysis of diesel engine piston

9.Finite element analysis and optimization of i.C. Engine piston using radioss and optistruct

AUThOR

Kola NagarjunaResearch Scholar, Department of Mechanical Engineering,Hyderabad Institute of Technology and Management,Hyderabad,India

Koyilakonda-Sumanth Assistant professorDepartment of Mechanical Engineering,Hyderabad Institute of Technology and Management,Hyderabad,India

Godi Subba RaoprofessorDepartment of Mechanical Engineering,Hyderabad Institute of Technology and Management,Hyderabad,India

Abstract

ijri-me-02-0011

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