FEDERAL MOGUL GOETZE INDIA LTD.

BAHADURGARH, PATIALA

INDUSTRIAL TRAINING REPORT

REPORT SUBMITTED BY
HARMANDEEP SINGH

ROLL NO.
11703003

REPORT SUBMITTED TO

DEPARTMENT OF

MECHANICAL ENGINEERING

PUNJABI UNIVERSITY, PATIALA

SUBMITTED IN PARTIAL FULFILLMENT OF

THE REQUIREMENT FOR THE AWARD OF

BACHELORS OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
 ACKNOWLEDGEMENT

Before I get into thick of things, I would like to say that it was a great pleasure and
privilege to explore the opportunity of undertaking training at FEDERAL MOGUL GOETZE
INDIA PVT. LTD for a period of 4 weeks as our 5th semester summer training under
MECHANICAL ENGINEERING DEPARTMENT of UCOE, PUNJABI UNIVERSITY,
PATIALA. I would like to thanks the FEDERAL MOGUL GOETZE INDIA PVT. LTD for
providing me such opportunity

I am sure that the knowledge and information that I have gained during this period would
be of immense value for my growth in the field of production. Finely, I would like to thanks
all those who singled out by name, to help me by sharing their immense knowledge gained
over years of experience.

In the end, I’m really indebted to my training teachers and have established such
marvelous professional training institute at BHADURGHARH, which provides a chance of
training to a number of professional. Students like us, and render all their help, assistance and
cooperation to them.
 ABSTRACT

This case involves the analysis, conclusions and hence the steps taken the
manufacturing of piston at the FEDERAL MOGUL GOETZE PLANT. It involves not only
the helpful collective data analysis but also lays emphasis on the various measures that ought
to be taken so as to reduce the losses in the piston production in this respective department
and hence, increase the growth, production and the retained profits of the plant in the ways
possible.
 TABLE OF CONTENTS

S.NO. TOPICS PAGE NO.

1. Introduction of Organization 6

2. Federal Mogul Brands 7-8

3. Major Costumers 9-11

4. Plants in India 12

5. Product Manufacturing in Patiala Plant 13

6. Departments 14

7. Process flow 15-29

8. Introduction of Piston 30

9. Operations 31-36

10. Profile Parameters of Piston 37-40

11. Surface Treatment 41-42

12. Conclusion 43
 LIST OF FIGURES
Fig.1 – Piston…………………………………………………………………………………12

Fig.2 – Piston rings………………………………………………………………………...…12

Fig.3 – Gudgeon Pins………………………………………………………………………...12

Fig.4 – Die Casting Furnace………………………………………………………………….15

Fig.5 – Scrap Melting………………………………………………………………………...16

Fig.6 – Induction Furnace……………………………………………………………………17

Fig.7 – The illustration shows dies used for casting………………………………………....18

Fig.8 – The dies are sprayed on with die paint to prevent any kind damage to the die &
prevent defects in casting…………………………………………………………………….19

Fig.9 – The Core is separated from the mould…………………………………………….…19

Fig.10 – This illustration shows how casting is removed with tong…………………………20

Fig.11 – Hand Operated Dies………………………………………………………………...22

Fig.12 – Piston Rings………………………………………………………………………...24

Fig.13 – Hydraulic cylinder………………………………………………………………….25

Fig.14 – Piston cylinder arrangement………………………………………………………..29

Fig.15 – Piston casting……………………………………………………………………….30

Fig.16 – OD turning/crown facing…………………………………………………………...30

Fig.17 – Spigot turning……………………………………………………………………….31

Fig.18 – Oil hole drilling……………………………………………………………………..31

Fig.19 – Rough pin hole boring……………………………………………………………...32

Fig.20 – Ultrasonic testing………………………………………………………………...…32

Fig.21 – Combustion bowl formation………………………………………………………..33

Fig.22 – Eddy current testing………………………………………………………………...33

Fig.23 – Valve pocket milling………………………………………………………………..34

Fig.24 – Aluminum & cast iron grooving…………………………………………………...34

Fig.25 – Finish surface turning……………………………………………………………....35

Fig.26 – Finish pin hole boring……………………………………………………………....35

Fig.27 – Circlip groove………………………………………………………………………38

Fig.28 – Length of piston…………………………………………………………………….39

Fig.29 – Phosphate coating…………………………………………………………………..40

Fig.30 – Graphite coating…………………………………………………………………….40

Fig.31 – Tin coating……………………………………………………………………….…41

Fig.32 – Anodizing………………………………………………………………………..…41
 INTRODUCTION

Federal-Mogul Corporation is a global supplier of automotive components, systems

and modules serving the world's original equipment manufacturers and the global
aftermarket. The company utilizes its engineering and materials expertise, proprietary
technology, manufacturing skill, distribution flexibility and marketing power to deliver
products, brands and services of value to its customers. Federal-Mogul is focused on global
profitable growth to create value for and bring greater satisfaction to its customers,
employees and stakeholders. Federal-Mogul World Headquarters is located at 26555
Northwestern Highway, Southfield, MI 48033, U.S.A. The Locations page provides more
information about these facilities.

Federal-Mogul design, engineer and manufacture a variety of automotive products for

our aftermarket and OE customers. Our products include, but are not limited to, bearings,
pistons, piston pins, rings and liners, valve seats and guides, dynamic seals, hot and cold
static gaskets and seals, liquid elastomeric molded (LEM) seals, systems protection, friction
products and aftermarket products (engine components, gaskets, antifriction bearings and
seals, brakes, chassis, wipers, fuel pumps, ignition and lighting).

Technological leadership matched with innovated thinking has made ESCORTS and
GOETZE products to enjoy a high degree of customer confidence and are the first choices of
discerning for application ranging from BI-WHEELER to BATTLE TANKS. The plant
manufacture over 3.4million & 2.9 million Piston-Pins & Crank Pins annually. Around 50%
of its production is being fitted by original equipment manufacturers of Automobile, Bi-
wheelers, Tractors, Stationary Engines, Generator etc. The company also directly supplies its
products to all the authorized dealers of the spare part for the above companies throughout
INDIA.

Federal-Mogul Goetze (India) Limited is the largest manufacturer of pistons and piston
rings in India Pistons are varying from 30mm to 300mm diameter. The most modern
production facilities at Federal-Mogul Goetze (India) Limited Patiala is certified TS 16949,
ISO14001 and OHSAS 18001.
 FEDERAL MOGUL BRANDS

For more than 100 years, Champion® has been one of the world's most
respected brands, providing a wide array of service replacement parts. These trusted products
include spark plugs, wiper blades and filters.

For more than a century, Ferodo® has led the development of friction
materials in their modern form. Ferodo offers brake pads and shoes, brake discs, brake fluids,
racing products and motorcycle products.

Federal-Mogul's Goetze® brand is a leading name in the automotive

world, offering quality piston rings and cylinder liners as well as a range of sealing solutions.

The Federal-Mogul Moog® line is the preferred brand of replacement

chassis parts by professional technicians. Our Moog products solve steering and suspension
problems and make installation easier.

Federal-Mogul's National® brand has built a reputation as one of the

most respected names in wheel end products. Our design team keeps pace with the industry
and provides advanced solutions to meet the needs of today's vehicles.

Niiral® is at the forefront of piston technology. Niiral has years of

experience in rapid product development, ultra-modern production technology and flexible
service.
 FP Diesel® heavy-duty engine parts and gaskets include a
comprehensive range of precision-engineered components for the construction, marine,
agricultural, mining, gas compression, trucking and industrial sectors.

Each year, Glyco® OE bearings are installed on more than 10 million

automotive, maritime and stationary engines, as well as on agricultural and construction
equipment.

The Federal-Mogul Payen® brand of gaskets, oil seals and cylinder

head bolts represents innovative design technology and strict manufacturing standards -
qualities that support our reputation as a trusted manufacturer to the automotive aftermarket.

PowerMAXâ„¢ spark plug wire delivers maximum protection and

maximum power.

The quality of Federal-Mogul Precision® Universal Joints can be seen

in all aspects of our parts, from our forged and case-hardened alloy steel crosses to our high-
quality, heat-treated needle bearings.

Raimsa is a trusted brand in Mexico that provides an extensive line of

kingpins, clutch-release bearings and hanger bearings.
 MAJOR COSTUMERS

I. COMMERCIAL VEHICLES:
 Telco
 Ashok Leyland
 Swaraj Mazda Ltd.
 Bajaj Tempo Ltd.
 Eicher Motors Ltd.
 State Transport Undertakings

II. BI-WHEELERS:
 Yamaha Motor India Private Ltd.
 Bajaj Auto Ltd.
 Kinetic Engineering Ltd.
 TVS Motor Company
 Majestic Auto Ltd.
 Enfield
 Hero Motor Corp.

III. TRACTORS:
Eicher Tractors Ltd.
Mahindra & Mahindra Ltd.
Escorts Ltd. (Td)
 Escorts Ltd. (Farmtrac Division)
 Mahindra Gujarat Tractor Ltd.
 HMT Ltd. (Td)
 Swaraj Engines Ltd.
 New Holland Tractors Ltd.
 International Tractors Ltd.
 L & T John Deer
 IV. PASSENGER CARS & JEEPS:
 Maruti Suzuki
 Hindustan Motors Ltd.
 Mahindra & Mahindra Ltd.
 Telco.
 Fiat

V. DEFENCE & RAILWAYS:

 Vehicles Factory, Jabalpur.
 Alco

VI. COMPRESSORS /AIR CONDITIONERS:

 Telco.
 Elgi Equipments Ltd.
 Voltas Ltd.
 Sundram Clayton Ltd.
 L & T - Komatsu Ltd.
 State Transport Undertakings

VII. STATIONARY ENGINES:

 Kirloskar Oil Engines Ltd.
 Ruston & Hornsby Ltd.
 Birla Yamaha Ltd.
 Greaves Lombardini Ltd.

VIII. INTERNATIONAL CUSTOMERS

 Chevrolet
 BMW
 Mitsubishi
 Ferrari
 PLANTS IN INDIA

Goetze (I) Limited has so far setup five plants in the different regions of India. These
Plants are named according to the name of the cities in which they are placed. The names of
the plants are as under: -

 Alwar Plant
 Bangalore Plant
 Bhiwadi Plant
 Patiala Plant
 Faridabad Plant.

OPERATIONS DONE AT FEDERAL-MOGUL GOETZE (I) LTD

 PISTONS – Melting, Alloying, Casting Machining, Anodizing, Inspection.

 PISTON RINGS – Melting, Alloying, Casting, Machining, Chrome Plating, Moly
Coating, Inspection.
 PISTON PINS – Machining, Heat Treatment, Inspection.

ANNUAL PRODUCTION

 PISTONS :- 13.57 MILLIONS

 PISTON RINGS :- 54.96 MILLIONS
 PINS :- 20 MILLIONS

PRODUCT RANGE

30mm to 300mm Dia.

 PRODUCT MANUFACTURING IN PATIALA PLANT

 PRODUCT:

Fig.1 - Piston Fig.2 - Piston Rings

Fig.3 - Gudgeon Pins

 PROCESSES:
o Melting.
o Casting.
o Cutting & machining.
o Inspection
o Packaging
 DEPARTMENTS

 Piston Foundry
 Piston Machine Shop-1
 Piston Machine Shop-2
 Light vehicle on Diesel (LVD) Shop
 Malden Shop
 Ring Foundry
 Ring Machine Shop
 SUKO Pin Plant
 Tool Room
 Compressor Room
 Generator Room
 Human Resources (HR) Deptt.
 Packing Deptt.
 Research & Development (R&D)
 Security
 Compressor
 General store
 Safety
 Ambulance
 Canteen
PROCESS FLOW
 MELTING SECTION

The first section of piston foundry is Melting section. In this section the alloys are
melted in certain ratio and then transported to other section. The principle metal for making
piston is Aluminum. So in melting section Aluminum is used in large scale. Some other
alloys are also used namely Silicon, Copper, Nickel, Magnesium. These elements are used for
good strength, ability to take fine surface, easy of casting and economical.

Fig.4 – Die Casting Furnace

 The industry purchase these alloys from

Al - Hindustan liver Ltd.
Si - Is Imported
Cu - Scrap
Ni - Is Imported
 There are five types of alloying elements in which ratio of alloys in fix.
CSA : Company Standard Alloy
(i) CSA 12
(ii) CSA 18
(iii) CSA 24
(iv) Bonding alloy
 100

90
90.55
80 83.2
70 77.1
70.6 Si%
60
Mg%
50 Cu%
40 Ni%

30 Fe%
Al
20

10

0
CSA-12 CSA-18 CSA-24 BONDING
ALLOY

Table no.1 – Composition of Alloying Elements

SCRAP MELTING: In the scrap melting the defected pistons are melted. There is no
need to add any alloy in it. Some scrap Piston from machine shop and other scrap piston
come from piston foundry.
There are many scraps in the piston. These can come with the gas or any other things:
(1) Cold Lap Scrap
(2) Depression Scrap
(3) Compressor Height Experian (CHE) Scrap
(4) Shrinkage Scrap
(5) Line Scrap

Fig.5 – Scrap Melting

 Induction furnace: Induction furnace is that furnace which can work on electricity
and it can be used to melt the material
 For melting there are seven types of furnaces out of seven, there are three induction
furnaces and four oil fired furnaces.
INDUCTION FURNACE: (a) Pioneer induction furnace
(b) Junker induction furnace
(c) Pillar induction furnace
- The maximum capacity of these induction furnaces in 1 ton. The furnaces (a) and (b)
has Main frequency with 250 KW and 50 Hz.
- The furnace (c) has Medium frequency with 500 KW and 200 Hz.

Fig.6 – Induction Furnace

 CASTING SECTION

The second section of piston foundry is casting section. In this section casting is done
on the several machines which are semi automatic and manual. There are about 50 semi
automatic and 3 manual die casting machines.

Fig.7 - The illustration shows dies used

for casting

Casting section of piston foundry is divided into five lanes, lane 1, lane 2, lane 3, lane
4 and lane 5. In these lanes there are different types of die casting machines.
a) MG-9C
b) MG-11
c) MG-7
d) MG-17
These all machines are semi automatic die casting machines. These machines work on
hydraulic mechanism.

These are three main parts of machine

(i) L.H.C. Outer part (mould)
(ii) R.H.S. Outer part (mould)
(iii) Core
The cane is further divided into three parts
(a) Middle core
(b) Side core
(c) Guide core
 Fig.8 - The dies are sprayed on with die
paint to prevent any kind of damage to the
die and prevent defects in casting

At the time of casting of pistons, the outer parts of the dies slides in opposite direction
and core slide in centre. With the help of pressure of compressed air, die is cleaned, than die
point is sprayed to provide insulation etc, to prevent from sticking of molten metal to it.
1. MG-9C: This type of machine is used for casting piston of dia 80mm and above.
It is used for casting one piston at a time.
2. MG-11: This type of die casting machine is used for medium die casting 60 to
80 mm. This is used for casting one piston at a time.
3. MG-7: For medium die casting (60-80mm) and casting for two pistons at a
time.
4. MG-17: For small size die casting less than 60mm and two pistons at a time.

Fig.9 – The core is separated from the mould

 Fig.10 – This illustration shows how casting is removed with the help of tong

MECHANISM: These machines are called gravity die casting machines. They are named
so because no pressure is used except that obtained from the head of the metal in the mould.
The moulds are made in two parts which can open or close in alignment in a horizontal plane.
The hollows or cavities in the interior are formed with steel cores. The cores are of moveable
type core. These cores can be separated from the mould. They are drawn before parting the
mould, as soon as the metal starts to solidify. It involves double pouring and used for casting
two pistons at a time.
There are four types of piston die casting machine :
(1) MG-7: MG-7 machine die can open in three parts First Centre tool left tool come
forward then the piston can come out from the die. This can make bigger piston such as
TATA, SONALIKA, and FORD etc.
(2) MG-9: MG-9 machine die can open in three parts first centre tool goes down word
and then the right and left tool come forward. Then piston comes out from the die.
(3) MG-17 & MG-11: MG-17 and MG-11 machine die can open in five parts in first type
centre tool can open in three parts and the centre tool can go downward and then the left tool
come forward and then it can go down and then the right tool comes forward and then the
piston can come out from the die. This can make small piston such as TATA, BAJAJ,
MARUTI, VESPA NV, RAJDOOT ETC.
These entire machines can work on water, Air, Gas and Hydraulic system. These three
things can differently work.
 (1) Water: Water can be use in this machine to cool the centre tool.
(2) Air: Air can be use to cool the outer mould.
(3) Gas: Gas can be use in this machine to heat the die.
(4) Hydraulic System: In this machine Hydraulic system to open and close the outer
mould.
MG-7 and MG-9 machine has a Bottom. But MG-17 and MG-11 machine has no
bottom. These machines have five or six valve. Firstly this valve can start and then machine
can work. This valve in the centre has a head and the right and left side has a coil and this
valve can work on Hydraulic system. In MG-17 and MG-11 have two dies and one mould.
This machine has no lift and in the machine MG-7 and MG-9 machine has one die there are
three tool centers, Right tool and left tool and centre tool. Machine MG-17 and MG-11 has
two holes :
(1) Window hole
(2) Pin hole
But machine MG-7 and MG-9 has only one Pin hole.
Procedure of Casting: (One die casting machines)
1. First of all safety precautions are taken and the machine is checked for the opening
and closing of die on manual/auto setting. Then casting spoon is pre-heated.
2. Die is then pre-heated as explained under
(a) When the die is in open state the controls are set up at auto operation and die
is closed on auto.
(b) The metal is then drawn from holding furnace and is poured into die with the
casting spoon.
(c) The die is opened manually after solidification is over. The casting is removed
and is placed on red bin. In the same way full casting are taken.
3. Then the core tools are assembled. Temp. Plate is placed on guide buss and a light
coat of tool paint is sprayed on tools with a spray gun. Also light paint is brushed on
the outer mould surface & bottom (MG-11 & MG-7 dies only).
4. The outer moulds are then closed and bottom is brought down as required; to
complete the assembly of die on auto cycle.
5. The fiber glass filter is placed on its seat & metal is poured into the die. After pouring
the foot switch is pressed to start the cooling cycle.
6. Die opens automatically when the cooling cycle completes.
 7. The castings produced are removed with the help of tong and placed on the cooling
channel.
8. The same procedure is repeated to produce more castings.
HAND OPERATED DIES: There is one Hand operated die which is used for casting.
Along with this there are twelve Dies for Billet castings. These Billets are then sent to forge
shop for forging of Pistons.
In these dies the outer die is of two parts with one end hinged and the other having
handle to operate it. The inner die is of five pieces which are placed in their respective
positions, so as to make the mould. While pouring is done these dies are titled and then they
are slowly brought to their original position. This is done to make the entry of molten metal
smooth and slow provide for uniform collage and avoid shrinkage cavity formation.

Fig.11 – Hand Operated Dies

PROCEDURE OF OPERATING MANUALLY OPERATED DIES:
1) The foremost step in making castings at any machine is to wear safety gloves and pre
heating the casting spoon.
2) Secondly the two halves are closed; locked and Pin sticks are inserted. Then by
keeping the mouth of casting spoon on pouring spout metal in poured into the
mould cavity.
3) After that the pin sticks are removed the moulds are unlocked and dummy casting is
removed, with casting rod.
4) Then the two halves are again closed and side tools are placed, small tools & centre
tools are also placed at their seats and the two halves are locked and pin sticks are
inserted and that completes the die assembly.
5) The die is pre-heated by making half castings.
6) The die is then opened with casting rod. Pin sticks are first removed, then small tools
are removed and then side tools.
The tools are hanged and Pin sticks are placed on its stand. By repeating the
procedure the dies are heated.
7) Then tool paint is sprayed on tools and bottom.
8) The die is then again assembled and titled with foot pedal and metal is poured from
holding furnace to the die. When the metal reaches up to Pin hold height foot
pedal is pressed to tilt back the die.
9) After solidification is over the die is disassembled. Every tool & pin sticks are cooled
in water tank till water bubbles are mild.
At last the tools are cleaned by sand blasting to make the surface rough, so that tool
paint could last long.
Making of ring carrier piston: These types of pistons are the pistons in which rings are
setup at the casting time. These pistons are bigger die pistons. They are casted on MG9 die
casting machines. Company has made these pistons for Tata 97 and 92 die, Escorts 372,
Sonalika and Eicher. The rings are of cast iron and import from other company. The surface
of rings is very plane so to make their rough surface there is a machine which is called shorts
blasting m/c.
Ring: The ring comes from the other company. The ring cannot be of pure Iron. This ring can
be made up of mixed metal. This ring is purposed in a piston to hard the piston. Firstly this
ring can be heated and then this can be put in a melting Aluminum and then this ring can be
put in a melting Aluminum and then this ring cannot work.
 Fig.12 – Piston Rings

Shot blasting machine: In this machine the rings are hung on the stands then the machine
shoted the small shorts of cast iron on the rings which with the help of a fan the shorts are
stick with the ring after 5 minutes the rings are ready, now their surface is quite rough. The
rough surface is important because if they are not rough then they can not stick with casting
properly.
Pipes in casting section: There are five pipes of different colour containing different things.
a. White - Oil
b. Yellow - Chlorine
c. Green - Water
d. Blue - Air
e. Pink - L.P.G.
These pipes are attached to every die casting machine.
Hydraulic System: Hydraulic system is the most important part of piston foundry because
without hydraulic pressure no machine can work properly. Because every machine is
operated hydraulically.
Working of hydraulic system: In this system the hydraulic oil is used. This oil in kept in the
container. Pump lifts this oil with the help of motor and the hydraulic pressure is produced.
This pressure goes to the dies casting machines, cutting machines and many other machines.
When the Hydraulic oil is used in a machine the water and the oil are mixed and then this
goes in a tank, the oil is used as in and again.
The machines are required at 49mg/cm2 to 50kg/cm2 pressure.
- This oil goes to the cylinder of machines
Working of hydraulic cylinder: When the oil enters from point B the oil pushes the valve
towards point A and the position 1 changes into position 2 Then oil enter from point A and
pushes back the valve to the position 1 and this process continues.

Fig.13 – Hydraulic Cylinder

Casting Defects:
1. Pin holes: There are very small holes revealed on the surfaces of casting. These types
of holes are called pin holes.
Cause: Gas dissolved in the alloy and alloy is not being properly degassed. So, by
proper degassing pin holes can be avoided in the casting.
2. Blow holes: Blow holes are smooth round holes visible on the surface of casting and
occurring below the surface of casting.
Cause: Gas is absorbed in the metal due to wet metal charge. Furnace atmosphere
which consists of water vapour and normal atmosphere gases. By controlling
properly, the above factors and proper degassing these defects can be avoided.
3. Cold laps: If two streams of metal which are too cold physically meet in the mold
cavity but do not fuse together. They develop cold laps defects.
Cause: 1. Too cold molten metal
2. Metal lacking of fluidity
4. Shrinkage defect: Metal shrinks as it solidifies. If this shrinkage is not compensated
by providing risers etc.

S.NO. DIE TYPE CASTING NO.

1 Bajaj M-50 40 L 190

2 Hero Puch 43 L 265

3 AX-100 50 L 212

4 RX-100 50 L 217

5 Bajaj Super 54 L 268

6 Bajaj Chetak 57 L 129

7 Vespa NV 58 L 226

8 Rajdoot 61 L 22

9 NV Model 58 L 242

10 LML-200 67 L 278

11 Rajdoot-350 64 L 205

12 Kinetic Pride 47 L 259

13 TVS-50 40 L 57

14 Safari 39 L 282

Table no.2 – Die type with Casting no.

 INSPECTION SECTION

Inspection is done to check the dimensions of the piston according to the drawings
available. In the inspection section first of all the visual checking of the piston is done, to
locate blow holes, shrinking, cracks, cold lap, extra material etc. Then the bottom thickness,
critical height, wall thickness, total height, eve distance, outer dia, leg dia, cavity volume and
slipper dia are measured.

DIE REPAIR SECTION

The major function of the die repair section is to check the conformity of the dies
according to the drawings of the piston. Basic objective is to check the various curves, major
dimensions and the tapers and to see that it any cuts are applied, occurring due to core
combination, then the corrections are applied by filing, welding and then by grinding. Here
the various checks are made through the two pistons from each die.

MAINTENANCE SECTION

The major function of the maintenance section is to maintain the machines of piston
foundry. The maintenance is divided into four parts.
1. Requisition Maintenance
In requisition maintenance small defects are removed by the maintenance department.
2. Preventive Maintenance
In this maintenance, routine checkup of all the parts of the machines is done before
and after every working shift.
3. Planned Maintenance
In this maintenance, the major defects of the machine are removed in a planed
manner.
4. Predictive Maintenance
 In this maintenance, the whole machine is checked and any part which is likely to
create a problem is replaced in advance.

250

200
Axis Title

150

100

50

0
HIND
HIND USTA
TATA SONA
AMBA USTA N TATA TATA ESCO ESCO FARM FORD
475 SI LIKA
SSAD N TRAC AC AC RT- RT- TRAC- 3610
ENGI 100
OR TRAC TOR 70¦Ö 7¦Ö 342 335 50 R/C
NE ¦Ö
TOR (DISEL
)
TEMPERATURE 210 205 205 205 210 210 210 210 210 205 210
TIME 5 4.5 5 5 4.5 4.5 4.5 4.5 4.5 5 4
HOUR 30 30 30 30 30 30 30 30 30 30 30

Table no.3 - Heat Treatment CSA – 12 Specifications

Chart Title
250

200
Axis Title

150

100

50

0
HERO
VESPA NV RAJDOOT TV 40 PUCH 65 LML TVS 43
CC
TEMPERATURE ºc 235 235 230 230 235 230
TIME 5.5 5.5 5 5 5.5 5
HOUR 30 30 30 30 30 30

Table no.4 - Head Treatment CSA 24 Specifications

 INTRODUCTION OF PISTON

FUNCTION OF A PISTON:

The functions which a piston is called upon to perform in an I.C. engine are:

1. To transmit the force of explosion to the crankshaft.

2. To form a seal so that the high pressure gases in the combustion chamber do not escape
into the crank case.
3. To serve as guide & bearing for small end of the connecting rod.

 DESIRABLE CHARACTERSTICS OF PISTON:

1. It should be silent in operation both during warming up & on normal running.

2. The design should be such that the seizure does not occur.

3. It should offer sufficient resistance to corrosion due to some product of combustion.

(Exp. Sulphur-dioxide)

4. It should have the shortest possible length so as to decrease over all engine size.

6. It must have long life.

Fig.14 – Piston Cylinder Arrangement

 OPERATIONS

 Fig.15 - PISTON CASTING

 Fig.16 - OD TURNING/CROWN FACING

 Fig.17 - SPIGOT TURING

 Fig.18 - OIL HOLE DRILLING

 Fig.19 - ROUGH PIN HOLE BORING

 Fig.20 - ULTRASONIC TESTING

 Fig.21 - COMBUSTION BOWL FORMATION

 Fig.22 - EDDY CURRENT TESTING

 Fig.23 - VALVE POCKET MILLING

 Fig.24 - ALUMINIUM & CAST IRON GROOVING

 Fig.25 - FINISH SURFACE TURNING

 Fig.26 - FINISH PIN HOLE BORING

 WASHING

 SURFACE HEAT TREATMENT

 PROFILE PARAMETERS OF PISTON

In the manufacture of pistons there are various problems that are being faced by the firms.
Some of these are:-

1. STEP ON GROOVE GROUND

With the step on groove ground, the ring does not fit properly and the piston assembly
could not be installed.

2. GROOVE WIDTH
Groove Width is one of the very important parameters of a piston because if the width
of the groove is more than the ring then the ring will be loose in the assembly and the
gases may escape from the ring surface to the bottom of the piston. Where, if the
groove width is less than the ring will not fit and the assembly could not be installed.

3. GROOVE DIAMETER
If the groove diameter is less than the ring will start fluttering and the gases may
escape from the piston top to the bottom of the cylinder. Where, if the diameter is
more, than the ring will not fit and problem will be faced during the assembly
installation.

4. WEIGHT
In case of multi-cylinder engines the pistons are assembled according to weight as it
has a lot of impact inside a running engine. The weight of the pistons are kept in the
range of ±2 grams because if there is too much variation in the weights of the pistons
inside a running engine than the pistons may exert an unbalancing force on the
crankshaft which may bend the crankshaft.

5. SKIRT SIZE
Skirt size is also one of the main parameters of the pistons. If the skirt size is more
than the given tolerance than it will seize the engine and if it is less than the
lubricating oil will start leaking and the lubrication will not be done properly.
 6. STEP ON SKIRT
A step on the skirt will increase the diameter of the skirt more than the tolerance
which may either damage the cylinder lining or seize the engine or both.

7. PIN HOLE DIAMETER

The PH. Diameter is also an important parameter which is being checked. If the
diameter of the pin hole is more than the pin will be loose, which will allow fluttering
of the pin causing damage to the boss. Where, if the pin hole is tight than the pin will
not pass through the hole

8. PIN HOLE SQUARENESS

The pin hole squareness means that whether the crown is perpendicular to the axis of
the pin or not. If the squareness is not ok than the piston will move in a tilted state and
will damage the cylinder lining.

9. PIN HOLE OFFSET(acc. to drawing)

In pin hole offset the pin is tilted horizontally. Offset is decided according to the
design of the connecting rod. If the offset is more than the required value, the
connecting rod may touch the skirt of the piston and damage it.

10. UNCLEAR PIN HOLE

If the pin hole is unclear than it will not result in smooth functioning of the pin, as the
pin will not rotate smoothly .

11. DAMAGE IN PIN HOLE

Due to damage in pin hole the pin will not operate properly.

12. STEP IN PIN HOLE

If there is step in pin hole, it will reduce the pin hole diameter and the pin will not be
inserted in the pin hole.

13. COMPRESSION HEIGHT

Compression height is another parameter which has an important role in the working
of the piston taken from center of pin hole to the crown of piston. If the comp. height
is more than the tolerances than it will surpass the T.D.C and will touch the cylinder
head and damage it.
 Whereas, if the comp. height is less than the tolerances than more fuel will start
entering the assembly which will result in lesser mileage and efficiency.

14. CAVITY
Cavity is another parameter of piston as according to drawing. The main function of
the cavity is to properly burn the mixture of air and fuel because if the fuel drops at
the centre of the cavity then the force is exerted mainly on the piston. Whereas, if the
fuel is distributed equally inside the chamber than the force is exerted equally in all
the directions and only a part of the force is exerted on the piston which produces
lesser power.

15. CIRCLIP GROOVE(Snap ring)

Circlip groove is a groove in the pin hole which is provided for the locking of the pin.
If the groove is not correctly made than the pin will not stay at its place and
connecting rod may move out of the assembly and seize the engine.

Fig.27 – Circlip Groove

16. CRACKS
These refer to the cracks which are present on the piston surface.

17. TOTAL HEIGHT

Total height refers to the length of the piston from top to bottom.

Where, if the height is increased from the top, it will touch the top of the cylinder.
 Fig.28 – Length of Piston

18. ROUGHNESS AVERAGE(Ra)

The roughness which is provided on the piston surface helps in retaining the oil film

19. GROOVE ANGLE

Groove angle should always be positive so that when the pressure is exerted from the
top the ring is sealed. Whereas, if the groove angle is already negative, the pressure
exerted will further increase the angle and result in more space and leakage of gases
will be there accompanying further consequences.

20. GROOVE WAVINESS

Waviness of the groove flank is checked. If there is waviness the ring will rest on
lesser surface area and will press the flank resulting in more space, which will result
in leaking of gases.

21. CONCENTRICITY
If the chamfer of the skirt is not concentric, the piston will move in a tilted position in
the engine which may result in eroding of the cylinder lining.

22. OPEN BORE

To regulate the weight of the piston, open boring is done on some of the casting
pistons. A cut as per the requirement is made on the boss.
 SURFACE TREATMENT

Phosphate Coating: Dark grayish color with thickness around 1 micron. It is used to
produce a crystalline corrosion resisting layer. This coating helps to have a good anti
frictional properties. Phosphate coating is done all over the piston.

Fig.29 – Phosphate Coating

Graphite Coating: Grayish black in color with thickness around 15 -25 microns. It is done
on the piston skirt and serves the purpose of emergency lubrication in newly assembled
engine till such time normal lubrication is attained. Graphite acts as a dry lubricant and
thereby prevents scoring / seizure of the piston till normal oil film is established.

Fig.30 – Graphite Coating

Tin Coating : Ceramic white coating with layer thickness 1-3 microns. It is used to ensure
smoother running in of the engine, better lubricated cylinder walls and freedom from cold
start scuffing. Tin coating may be done all over the piston or with the exception of gudgeon
pin hole.

Fig.31 – Tin Coating

Anodizing: Grayish layer of Aluminum oxide done on piston crown with thickness around
five microns. Anodizing is done due to the fact that during combustion process, piston crown
is exposed to very high temperatures. In order to avoid development of cracks in the piston
crown due to thermal stresses, the upper layer is hardened by specialized anodizing process.
This also prevents corrosion of piston crown.

Fig.32 – Anodizing

Moly Coating: Black in cooler with layer thickness 5 -15 microns. Coating acts as anti
friction layer which prevents pistons from scuffing during cold start. In some applications,
this coating is also provided to reduce clearance, thereby reducing noise phenomenon. Unlike
graphite coating this coating should be intact throughout the life of the piston.
 CONCLUSIONS

 A shape of the head of piston has a major effect on different parameters of a DI Diesel
Engine. Different shapes include FP, FBP, BP and IBP has its effect on tumble ratio and
TKE. All changes in head design are mostly for attaining turbulence of flow mixture which
causes better air-fuel mixing.

 A modified proposed design of tangential swirling groove on piston head varied depth and
2mm thickness are analyzed on AVL and its has more swirling action as compared to all
other piston head design.

 This modified head design has major effects on increasing the BSFC, Brake thermal
efficiency, pressure inside chamber and outlet air temperature.

 Also proper combustion will reduce the emission of toxic gases.

 Thus this newly modified design of tangential swirling groove on piston head of a DI
Diesel Engine has major effect on the properties of DI Engine.

 Using the shape optimization techniques with Hyper-Study,

 for the connecting rod, a mass reduction of 9% was achieved.

 for the piston, a mass reduction of 11% was achieved.

Satisfying the restraint and manufacturing restriction

 Defining the design variables based on the PRO/E model history, the optimized shape
was easily transferred to the CAD design.

 HMC has applied the optimization techniques using Optistruct, Hyper-study for weight
reduction or durability increase of the other engine components.