Assignment Of Manufacturing Processes

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 today’s 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 correctly-

tuned 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.