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• Cast aluminum alloy is lightweight and has good structural integrity and
low manufacturing costs. The light weight of aluminum reduces the overall
mass and force necessary to initiate and maintain acceleration of the
piston.
• Piston rings are generally manufactured from cast iron or stainless steel .
Piston Manufacturing Process
•The material is then scooped up with a ladle from the crucible (the
pot that holds the molten material). The material is then allowed to
cool .
2) DEHORNING , HARDENING AND MACHINING
• Then in a lathe machine , the rough edges are cut and a smooth
profile is obtained by means of a turning operation.
3) CNC LATHE MACHINING
• This process involves the final size being machined of the piston. The
grinder machines the skirt of the piston only and in the majority of
cases is cam ground. Cam grinding ensures the piston will "grow"
evenly in the bore of the engine .
Final Inspection
• At this stage the piston is cleaned, fitted with the appropriate wrist
pin, stamped with the pistons oversize and any other markings, and
then sent to dispatch.
MANUFACTURING BY FORGING
1 ) 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.
2) THE PUNCH
• A punch press and dye are pre-heated while the slug moves through an
oven, heating it to 426 C° 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
cool
MANUFACTURING BY FORGING
3) 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.
•
4) The Wrist Pin Holes and oil control 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
• Oil control holes are drilled along the
5) Ring Grooves
• Three ring grooves are created by a Lathe machine
5) The Milling machine
•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.
5) Grinding
• The next step involves grinding of the piston from it’s head to give the crown the shape
required according to the design . A lubricant is used to cool the work piece continuously.
6) 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 smooths out the sharp edges of the piston created
during production. The holes created for the wrist pin are then put
through a machine which smooths them, allowing the wrist pin to fit
comfortably.