Summer Training Report On Manufacturing of Camshaft & Valve Tappet

Presented By:-

PRITHVI RAJ SONI SOURABH PUROHIT

Company Profile
MAHLE is leading global development partner for the automotive and engine industry. MAHLE offers unique systems competence in the combustion engine and engine peripherals. MAHLE has a local presence in all major world markets. In 2014, some 65,000 employees at 140 production locations are expected to generate sales of around ten billion euros. At ten major research and development centers in Germany, Great Britain, the USA, Brazil, Japan, China, and India, more than 4,000 development engineers and technicians are working on forwardlooking concepts, products, and systems. MAHLE Engine components Pvt. Lmt. Is located in Pithampur district, near indore

INTRODUCTION
CAMSHAFT

Camshaft is engine component which converts rotatory motion into reciprocatory motion. A camshaft is a shaft to which a cam is fastened or of which a cam forms an integral part

VALVE TAPPET
Mushroom Head Cylindrical

A tappet is a projection which imparts a linear motion to some other component within a mechanism. The tappet is that part, also termed a cam follower that runs on the camshaft and is made to move vertically by

the action of the rotating cam.

VARIOUS DEPARTMENTS FOR MANUFACTURING PROCESSES OF CAMSHAFT & VALVE TAPPET

Green Sand Foundry

Shell sand Foundry

Machining Inspection & Quality Control

GREEN SAND FOUNDRY

Green sand casting is a metal casting process characterized
by using sand as the mold material. Sand is moistened, typically with water, but sometimes with other substances, to develop strength and plasticity. "green sand" is not a type of sand on its own, but is rather a

mixture of silica sand (SiO2), or chromite sand (FeCr2O), or

zircon sand (ZrSiO4), 75 to 85%, or olivine, or staurolite, or graphite.

There are six steps in this process:

1. Place a pattern in sand to create a mold.

2. Incorporate the pattern and sand in a gating system. 3. Remove the pattern. 4. Fill the mold cavity with molten metal. 5. Allow the metal to cool. 6. Break away the sand mold and remove the casting.

SHELL SAND FOUNDRY

Shell mold casting, is an expendable mold casting process that
uses a resin covered sand to form the mold. As compared to sand casting, this process has better dimensional

accuracy, a higher productivity rate, and lower labor

requirements. Shell mold casting allows the use of both ferrous and nonferrous metals, most commonly using cast iron, carbon steel, alloy steel, stainless steel, aluminum alloys, and copper alloys.

The shell mold casting process consists of the following steps:

1. Pattern creation - A two-piece metal pattern is created in the shape of the desired part. 2. Mold creation - First, each pattern half is heated to 175-370C (350-700F) and coated with a lubricant to facilitate removal. The heated pattern partially cures the mixture, which now forms a shell around the pattern. 3. Mold assembly - The two shell halves are joined together and securely clamped to form the complete shell mold

4.

Pouring - The mold is securely clamped together while the molten metal is
poured from a ladle into the gating system and fills the mold cavity.

MACHINING PROCESSES
Following machine tools are used in maching of valve tappet 1. Pre-grinder (plunge an through feed) 2. Hardness tester 3. Multi Spindle m/c & CNC m/c 4. Heat treatment

5. Lapping m/c
6. Crack testing m/c

CENTRELESS GRINDING MACHINE

The centreless grinder is a type of grinding machine used to shape the outside of an object. Centerless grinding is a form of grinding where a regulating wheel positioned on the opposite side of the object to the grinding wheel.

A work rest keeps the object at the appropriate height but has no
bearing on its rotary speed.

MULTI SPINDLE MACHINE

It can provide the various types of machining such as boring,

turning, chamfering, threading, grooving, and drilling by moving the work pieces between 6 or 8 stations simultaneously.

Generally Multi Spindle Automatic Lathe can provide approx. 4

5 times of machining speed comparing to the Single Spindle Lathe

LAPPING MACHINE

Lapping is a superfinishing machining process. Two surfaces are rubbed together with an abrasive between them, by hand movement or by way of a machine.

HEAT TREATMENT
Heat treatment is to increase service life of a product by increasing its

strength or hardness, or prepare the material for improved

manufacturability. Heat Treatment Processes Hardening Annealing Normalizing Tempering

FINAL INSPECTION
NITRIDIN TAPPET
VISUAL INSPECTION- I DIMENSIONAL INSPECTION VISUAL INSPECTION- II OIL PACKING