Piston Design

Piston Designs Ltd Invoice No.

Document No.
# 713204

SR20DE PISTON

The following is a release document for a piston for a Nissan SR20DE/SR20DET engine. The pistons are to be
forged from 4032-T6 aluminum and then machined to the desired shape.

Prepared By: To Be Checked By: To Be Approved By:

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INTRODUCTION

The pistons are designed for a Nissan SR20DE / SR20DET engine, they are to be forged from 4032-T6
aluminum and then machined to the desired shape. They are 86.5mm in diameter, 60mm in height, and
have a compression height of 32mm.

MACHINING AND CUTTING

Rods of 4032-T6 aluminum alloy 86.5mm in diameter should be cut into 60mm long slugs. The
punch press and die should be heated to the same temperature as the slugs. Once the forgings
have cooled they are required to be heat treated twice more, the second time at a lower
temperature then the first. The pistons need to be machined on a lathe to ensure they are
dimensionally correct; four holes on each side need to be drilled, each 2.4mm in diameter, for
lubrication. Grooves then need to be cut for the two compression rings and one oil control ring. A
22mm diameter hole needs to be drilled for the wrist pin and then the sides need to be shaved, this
hole should then be smoothed and the lock ring grooves at both ends need to be cut. The dish on
the head of the piston should then be cut, and then the model and production should be engraved
on the piston head.

SPECIFICATIONS AND TOLERANCES

The piston must be very precise dimensionally as it will expand while in use. The
piston is designed to be 86.5mm in diameter and 60mm in length. The wrist pin is 22mm in diameter
with a 1.2mm diameter lock ring at both ends. The piston must have a compression height of 32mm
and an overall weight of 500g . Refer to the attached sheet for specific dimensions. The
batches of the end product must be very similar in weight; therefore these tolerances must be kept.

SURFACE FINISH

Where necessary a finishing cut of 0.15mm should be applied. All sharp edges are to be belt sanded
and each piston is to be inspected for any imperfections. All traces of lubricant are to be removed by
the use of high pressure jets spraying hot de-ionized water and then dried with an air gun. Each
piston is to be inspected by man for any imperfections; if the piston passes the inspection it is to be
packaged securely for storage and shipping.
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MATERIALS

Pistons are to be forged from Aluminum 4032-T6, the main composition of this is as follows:
Aluminum 81.1 – 87.2%
Silicon 11.0 – 13.5%

The following elements are also present in amounts up to 1.30%:

Chromium, Copper, Iron, Magnesium, Nickel, and Zinc

STANDARDS AND QUALITY

One in every 20 slugs should be inspected once it has been forged to ensure it is dimensionally
accurate. The pistons are to meet the ISO 9001:2008 standards in quality manufacturing. All pistons
must have a clean surface, free of lubrication, and must be in the weight error range of ± 0.1%

REFERENCES

ISO Standard
http://www.iso.org/iso/catalogue_detail?csnumber=46486
Material Datasheet
http://www.matweb.com/search/datasheet.aspx?matguid=35707660584d4f7caef591324e592396&ck
ck=1

VIEWS
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REASONS FOR SPECIFIC MANUFACTURING PROCESS

Machining and Cutting

The forging process reduces the overall process time by providing a rough shape. The CNC machining processes
have to be very accurate to ensure that the tolerances are kept to a minimum and therefore the weight of each
piston is kept the same.

Specifications and Tolerances

The pistons must be kept within the dimensional tolerance of to ensure that the overall weight
is kept within the .

Surface Finish

Before the pistons are packaged they are to be inspected by man for any imperfections, this is to ensure safety
and quality as any scratch may result in fracture and/or engine damage.

Materials

Aluminum 4032-T6 has an excellent surface finish when using polycrystalline or carbide tooling. It has superior
wear resistance, high strength, and low thermal expansion.

Standards and Quality

One in every 20 slugs should be inspected once it has been forged to ensure it is dimensionally accurate. The
pistons are to meet the ISO 9001:2008 standards in quality manufacturing. All pistons must have a clean
surface, free of lubrication, and must be in the weight error range of .