Sie sind auf Seite 1von 29

SHRIRAM PISTONS AND RINGS LTD. WORKS ENGG.

TRAINING REPORT

PREPAIRED BY
SHAMIM KHAN
PISTON PLANT

COMPANY PROFILE

Shriram piston & rings ltd. Is a part of well

known Shriram Group of Companies (Group turnover Exceeding RS..500 crore) company is presently engaged in manufacturing of I.C. engines components such as pistons, rings, gudgeon pin, engine valve & gears in collaboration of world leaders like Kolbe smithof Germany & Honda foundry of Japan for pistons, Riken Corporation of Japan for rings, and Fuzi Oozxof Japan for engine Valves. Companys product under USHA brand named are exported to over 60 countries world wide including reputed OEMs. The company has QS 9000, TS-16949 & OHSAS-18001 accreditations & has recently bagged the TPM excellence award from JIPM, Japan. There is approximate 3628 employees in the company.

COMPANY LOCATION
Shriram pistons & rings ltd. Plot No. A -6 & 7

Meerut road gzb. . It is a big company in a ghaziabad city.

S.P.R.L. SECTIONS AND THEIR COLLABARATIONS


PISTON PLANT

Collaborated with KOLBENSCHMIDT (GERMANY) for diesel engine piston & HONDA FOUNDARY (JAPAN) for petrol pistons.
RING PLANT

Collaborated with RIKEN CORPORATION (JAPAN)


ENGINE VALVE PLANT

Collaborated with FUZI OOZX (JAPAN)


PIN PLANT

Self technology.
NSG PLANT

SAFETY Safety is the meaning that, where we are working in any work place then we should ensure all safety about workplace. And also we have knowledge about all safety equipments. Different workplaces in Aluminum Foundry we should use shoe, goggles, helmet, hand gloves, apron, leg guard, etc. these all safety equipment is very important for safety.

COMPANY ACHIVEMENTS
1993:- Commissioning of E.V. plant 1994:- ISO-9001 for piston plant, pin plant,

ring plant.
1995:- Commissioning of most model line for

diesel piston.
1996:- Exclusive supplier status with (T.C.L.) 1997:- ISO-9001 for E.V. plant. 1998:- Best vendor award (Marti Suzuki). 1999:- QS-9000

Best supplier award (TCL)


Export performance award (E.E.P.C.) ACMA quality award 2001:- ISO-14000 2003:- TS-16949, OHSAS Certification 2004:- Commissioning of automatic line for

piston plant.

5S

SIERI SEITON

SESO
SHIKETSU SHITSUKE

SEIRI:- Selection of right thing.

SEITON:- Systematic arrangement of


gauge, fixture, material. SESO:- Sparkle cleaning. SHIKETSU:- Standardization. SHITSUKE:-Self discipline. 5S is use in every company. There is a very best example of 5s. This is from Japan.

TPM

TOTAL PRODUCTIVE MAINTENANCE TOTAL:- Participation of all employees of an organization. PRODUCTIVE:- Maximized efficiency by minimizing losses and rejection. MAINTENANCE:- Entire production system maintenance. There is three types of losses. MACHINE LOSS MATERIAL LOSS MANAGEMENT LOSS There are 12 pillars of TPM.

JISHU HOZEN KOBETSU KIZEN HINHITSU HOZEN PLANNED MAINTENANCE EDUCATION & TRAINING INITIAL CONTROL OFFICE TPM SAFETY 7 ENVIRONMENT R & D PRODUCT LOGESTIC INFORMATION MANAGEMENT MARKETING NETWORK

PER HOUR METAL MELT CAPACITY POWER CONSUME OF FURNACE

PIONEER FURNACE-

kwh/ton

Melt capacity = 500 kg/hr. Power Consume = 630

VIDYUT AGNI FURNACE-

630kwh/ton

Metal capacity = 300kg/hr. Power Consume =

INDUCTOTHERM FURNACE-

Metal capacity = 1000kg/hr. power consume = 613kwh/hr Metal capacity = 1000 kg/hr. H.S.D. Consume = 100

S.K. FURNACE-

Ltrs/Ton

OBJECT OF HOLDING AND METAL TREATMENT

HOLDING AND METAL TREATMENT


Slag/Dross Removal. Degassing Using Tablets And Nitrogen & Chlorine Gas.

Determination of Hydrogen gas.


Grain Refining so good Microstructure. To Obtained as per Chemical Composition.
SLAG/ DROSS REMOVAL

Cover Flux is used for Dross removal. To Minimize Metal Loss


Dross removal Cover Flux is suitable because it is free from Sodium salts, as chloride salts of sodium deplete magnesium
DEGASSING

Liquid Aluminum dissolve Hydrogen G.B.F { Gas Bubble Fixture } unit is used to remove the Hydrogen gas from the metal otherwise it raise the tendency of inclusion and gas porosity defects. Nitrogen and chlorine gas are to be used as
degasser.

Gas Bubble Fixture


Principle :- Impeller Principle in which

rotor mixes aluminum with inert gas, preferably Nitrogen and produces a mixture of metal and very fine gas Bubble
RPM of rotor = 400 500 rpm. Flow Rate = 1 2 Kg/Hr/

Grain Refining
It is done to improve the size of primary

Aluminum grains.
Improve size of grain. Improve Mechanical properties Reduce Surface Porosity Inspection Gas Sample Free from gas (porosity). Fracture Sample. Good Micro structure. Chemical Composition as per Standard Temp. as per Std. Metal free from dross , inclusion & other

impurities

CASTING

Casting is a manufacturing process to produce component of required dimension, shape which include all the allowance. Casting mainly of two typesSend casting Die casting

Die casting also of three typesGravity die casting:- The pouring of metal by gravitational power LP Die casting:- The pouring of metal on 4kg/cm2-6kg/cm2 HP Die casting;- The pouring of metal on 50kg/cm2-150kg/cm2 We are using Gravity Die casting. EQUIPMENTS Gravity Die Casting machine:This machine is a 2- cavity automatic piston casting machine. It is controlled and operation by hydraulic and electric system. Automatic centralized lubrication unit, oil lubrication. Operation pressure 30-40kg/cm2. it is operated by a control panel.

METHOD OF CASTING

In the gravity die casting, molten metal pouring by the spoon from holding furnace to machine dies rumor. After some time automatically die open and casting make with riser.
CASTING DEFECTS: Cold shut Shrinkages Cutting Inclusion Blow hole air

Dimensional
There is four bays for piston casting: RCP( ring carrier piston) bay. NON RCP bay. Petrol bay.

Ford & Renault


We are using the two types of gravity die casting machine. Honda type die casting machine KS (kolbenschmidt) type die casting machine.

RISER CUTTING

After casting pistons send for riser cutting to sonicut machine/Ancillary party.
EQUIPMENT:-

Side guards for safety. Coolant flow for tool cooling. Clamp device for better clamping.
OUTPUT:-

After cut the riser, put the piston alloy wise and model wise in the basket. Check the pistons for riser cutting, over riser or under riser. Piston should not above 3 mm after riser cutting. We use gauge for check it. Piston should be clean, coolant not enter inside. Now clean it with air.

HEAT TREATMENT
OBJECT OF HEAT TREATMENT:-

To relive internal stresses, which are set in the metal due to cold or hot working. To soften the metal. To improve hardness of the metal surface. To improve machinability. To refine grain structure. To improve mechanical properties like tensile strength, ductility and shock resistance etc. To improve electrical and magnetic property. To increase the resistance to wear, tear, heat corrosion.
AGEING

Dimensional or volumetric stability or stability in piston size- Piston alloy has a property that it changes after some time. If we machined a piston casting without heat treatment then we found after some days that piston size has changes or over size. If we fit this piston in engine, it will create problem in engine. So to reduce this problem we do heat treatment of pistons. Heat treatment process has done before machining so, that no change found in piston after machining. Its process called AGEING. Hardness and strength of piston both increase by AGEING. Piston have a shining after machining by heat treatment otherwise piston appear white.

SOLUTIONIZING

Hardness and tensile strength increase of piston by solutioning also AGEING process to be done after solutionizing otherwise solutionizing is a incomplete without AGEING. Solutionizing use for those models which have thin wall thickness and use in high speed engine.
CONTROL POINTS

Only two rows arrange in each basket. Load the basket on loading table forward mark. Mark with yellow paint before sand. Water temperature should be 60-80 0C. Time 110 minutes and temp. 505 0C in solutionizing. Time 110 minutes and temp. 205 0C in ageing. Take 1% piston to check hardness from each basket.
QUENCHING TIME

Quenching time should be very less. If it increases then piston hardness also found.

INSPECTION
VISUAL INSPECTION

There are many types of inspection of pistons;

Check metal cutting and metal sticking in piston. Check the shrinkage in piston. Check it for high deep. Pin bore should not closed no fin observed in pin bore. Check sand core in piston it should be proper. Metal should not sticking on the parting line of the piston. Sand should not broken of riser or ingot.
DIMENSIONAL INSPECTION:

Dimensional inspection has done by three type. First piece inspection. Regular line inspection Critical/ Special parameter inspection.
DIMENSIONAL PARAMETER FOR PISTONS:-

Crown thickness. Boss distance. Wall thickness Wall thickness variation (WTV). Boss radius thickness variation (BRTV). Head tilt. Core depth. Core depth cavity height. Edge cast. Weight.

HARDNESS TESTER: there are two types

Brinell Hardness testing machine Rockwell hardness testing machine. Brinell hardness testing machine use for RCP/NON RCP and NON HONDA models as Bajaj, Maruti, Lohia Hardness check. Rockwell hardness testing machine use for Honda Models hardness check..

SPECTROMETR: Use for check the chemical

composition of Al-Si alloy. PRINCIPLE: when we generate spark on sample by Tungsten Electrode on 18000 volts then spark light entire in a vacuumed chamber by a slit. Where light energy absorbed by PMT, fit on different wavelength according to different element, and PMT convert this light energy to electric energy (in MV) and send to computer

ANALYSIS MICROSTRUCTURE ANALYSIS: we take

many sample before casting from molten metal as spectro sample, GP sample fracture analysis to check metal refinement or to check grain size then start casting.
PROCESS: Cut a piece from pin bore or crown area. Grind it on 60 grit emery paper. Then polishing/file grinding on 320, 400, 600 grit emery paper. BUFFING/ FINAL POLISH Use of blue, red or olive oil lubricant with

diamond paste on adhesive sloth/ velvet cloth.


Set the microscope on 100 magnification

and compare the sample with standard microstructure photo.


Primary silicon crystal size should not

more than 100 micron


Si crystal should not segregate. Refinement of primary silicon should be

proper.

DIE REPAIR
DIE PARTS:

1. 2. 3. 4.

Core assembly: Central tool Side tool Eye pad Guide ring Bottom die Mould assembly Quill pin

EQUIPMENTS: CNC lath machine- for accurate

machining/ turning profile. Sander Grinder-It is a electric tool run by carbon on 12000 rpm. It is used for cut rough surface with the help of sander wheel, wheel size is 100mm *4mm *16mm. Pneumatic grinder- This equipment start with air on 20000 rpm and used for rough finishing, rough surface, profile radial making. Carbide bur- To cut hard surface used tungsten carbide bur. Tig welding M/C.- use for welding on job. Filler rod Use 5 HSS electrode for petrol engine die. Use SS310 electrode for diesel engine old die.

DIE MATERIAL:

The material use for core, guide ring, bottom, die is H.D. Steel

MOULD MATERIAL:

mould material is EN-19 or p 20


DIE PREPERATION Blasting the die by glass bed after stress

relieving. After clean it with emery stone or emery paper now check the die for distortion or Damage on surface place during stress relieving. Check the gap between each assemble part by filler gauge minimum gap should be 0.05mm.

DIE PAINTING AND SETTING Need of Die painting:- To improve the pistons
quality and to control on rejection. Benefits of die painting; By die painting we reduce cold shut and shrinkage defects. To use of die painting we make sage of dies from rust and corrosion. To make smooth movement between die parts. Types of paints:1. A-39 2. HPF-11 3. R.I.O. 4. L.N.O. 5. Honda paint 6.DIE COAT PAINT39 7. GRAPHITE PAINT 6. INSULAR 700 MITTI. Preparation of paints for use:1. R.I.O. + Water 275-325 gm 180-220 ml life time= 4-6 days 2. L.N.O. + Kerosene oil 90-110 ml 290-310 ml life time= 46 days 3. H.E.P. + Water 90-110 ml 65-85 ml life time= 4-6 days SHOT BLASTING:To remove rust it is very important we should shot blast of die parts. In the shot blasting e use shots of aluminum oxide and glass bead on a air pressure by 3-4 kg/cm2. for shot

METHOD OF DIE PAINTING:

To take die from die section Air root should be opened and not rusted. To give heat till die color to be light brown or light in the electric or gas oven. Asbestos flak coating. ( for RCP dies use insular mitti in ingot) pocket. R.I.O. Paint in Runner and Riser By brush. H.E.P. -001 paint use in mould inner side. Graphite paint use in those paints where are use for movement. After paint of all parts to heat up in oven.

DIE PARTS: Moulds Bottoms Eye Pad Center tools Side tools Guide ring Tie rod and springs Quill pins

METHOD OF DIE SETTING


At first to the inspection of machine and all movement check in manual mode. Centre tools fit in centre tool slide. Side tools adjusting in centre tool. Base plate fixed on the machine bed. Eye pads assemble on the base plate. Mould setting on the machine bed. Quill pins and cooling pipes setting in the mould. Bottom setting in the bottom holder. After all setting set machine parameters. It is the more important to pre before casting because if the die is cold at the time of casting, cold die problem come in the casting.

THANK YOU

Das könnte Ihnen auch gefallen