qwertyuiopasdfghjklzxcvbnmqwertyui opasdfghjklzxcvbnmqwertyuiopasdfgh jklzxcvbnmqwertyuiopasdfghjklzxcvb Manufacturing Processes nmqwertyuiopasdfghjklzxcvbnmqwer project tyuiopasdfghjklzxcvbnmqwertyuiopas Topic: Motorcycle Carburetor dfghjklzxcvbnmqwertyuiopasdfghjklzx Prepared by: cvbnmqwertyuiopasdfghjklzxcvbnmq

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Contents

Page no.

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Introduction and History of Motorcycle carburetor Carburetor Function and Construction Carburetor Size Carburetor diameter and Carburetor Design Criteria Carburetor Design Material of Motorcycle Carburetor Manufacturing of Motorcycle Carburetor Aluminum Die Casting Cold Chamber Die casting Machine Equipment of Manufacturing Boring and CNC Machining Grinding Reaming and Die Casting Tooling How Dies are made? Means of Serving Market Equipment Layout and Estimated Cost Conclusion

3 4 6 7 8 10 11 12 13 13 14 15 16 17 18 19 20

Introduction:
A carburetor is a device in a motorcycle's engine that combines vaporized fuel with air before ignition. It gets its name from the French word "carbure" which means carbide, or to combine with carbon. For about a hundred years, carburetors were the components of choice for fuel delivery in vehicles.

History:
Year 1882 Scientist Name Enrico Bernardi Invention Developed first Carburetor combustion engine. for first petrol

1884

Karl Benz

Developed a Carburetor for Internal combustion engine.

1885

Wilhelm Developed a float carburetor for their engine based Maybach and Gottlieb on the atomizer nozzle. Daimler Siegfried Marcus Invented the rotating brush Carburetor.

1893-

1893

Janos Csonka Donat Banki Fredrick William

and Further improved the rotating brush carburetor.

1896

Experimented with wick carburetors in cars.

Carburetors were the usual fuel delivery method for most U.S. made gasoline-fueled engines up until the late 1980s, when fuel injection became the preferred method of automotive fuel delivery.

Carburetor Function:
A motorcycle engine requires around 10 milligram of gasoline per stroke. The function of the carburetor is to mix the correct amount of fuel with the air so that engine runs properly. If there is not enough fuel mixed with the air, the engine "runs lean" and either will not run or potentially damages the engine. If there is too much fuel mixed with the air, the engine "runs rich" and either will not run (it floods), runs very smoky, runs poorly (bogs down, stalls easily), or at the very least wastes fuel. The carburetor is in charge of getting the mixture just right.

Construction:
The main components of motorcycle carburetor are: Float chamber The float chamber holds a quantity of fuel at atmospheric pressure ready for use. Its supply is refilled by a float driven valve; the float drops or rises to open and close the inlet that delivers fuel to the float chamber. Venturi and throttle In a motorcycle carburetor, air passes through a venturi into the inlet manifold of the engine. Venturi creates a vacuum by increasing the speed and lowering pressure (Bernoulli principle). A butterfly valve called the throttle is used to control the air flow. It is connected to the accelerator. This valve controls the amount of air/fuel mixture delivered to the engine through the venturi, and therefore also controls the engine's speed and power.

Idle circuit When the throttle valve is closed a small amount of fuel and air gets through small openings located after the butterfly valve. This is called the idle circuit and it enables the engine to keep running when there is no pressure on the accelerator. Mixture Needle: It regulates the flow of fuel to the jet. When the needle is down it prevents fuel from flowing and is in ideal cutoff position and when it is up it delivers maximum fuel. Choke Its purpose is to restrict the flow of air, thereby enriching the fuel-air mixture while starting the engine. By restricting the flow of air into the throat of the carburetor, the choke valve reduces the pressure inside the throat, which causes a proportionally greater amount of fuel to be pushed from the main jet into the combustion chamber during cold-running operation
Throttle valve Idle jet

Mixture Needle

Fuel Venturi

Float valve

Jet

Outside Air

Float chamber

Carburetor Size:
Following factors are involved in determining size of a carburetor:
1) Engine Displacement: Engines are sized by displacement. Displacement is a measurement of the volume of air/fuel the engine can use in a single rotation of the crankshaft. A 350 cubic inch engine will suck in and push out 350 cubic inches of air/fuel in a single rotation of the crankshaft. 2) Engines are measured in cubic inches. Carburetors are measured in cubic feet. To convert from cubic inches to cubic feet, multiply by 0.0005787. 3) For 4 stroke engine n=N/2. 4) Maximum rpm limit: Since motorcycle engine displace a certain amount of air/fuel per revolution, the number of revolutions per minute is important. 5) Volumetric Efficiency: Very few engines actually operate at 100% volumetric efficiency. This means that even though an engine is rated at 350 cubic inches, it will actually displace slightly less. Most production engines operate between 70% and 85% volumetric efficiency.

Putting these five facts together gives us this formula: (A * 0.0005787 * B) / 2) * C = carburetor size A = Engine displacement in cubic inches B=Maximum RPM C = Volumetric Efficiency as a percent (100% = 1, 50% = 0.50). For CD70 bike Engine displacement = 72.00 cubic cm (4.39 cubic inches) Maximum RPM = 11,500 rpm Volumetric Efficiency = 87% approx Hence the carburetor size should be 12.71 Cubic feet per minute (CFM) i.e. 12.71 cubic feet of gasoline is sucked by engine per minute.

Carburetor Diameter:

Carburetor diameter (mm) =

Where n=maximum RPM s=stroke (mm) D=bore(mm) v=gas speed (45-60 m/s) For CD70 Bore = 47.0 mm (1.9 inches) Stroke = 41.4 mm (1.6 inches) N= 11500 rpm V = 60 m/s Carburetor diameter = 24.1 mm

Carburetor design criteria:

The carburetor is designed to perform three basic functions: 1. To control the power delivered by the engine, adjusting the airflow inducted according to driver demand. 2. To meter the fuel flow into the inducted air stream, while keeping the air/fuel ratio in the optimum range over the engine's entire working range. 3. To homogenize the air and fuel mixture in order to make the ignition and combustion proceed properly.

Carburetor Design:

1. Starting lever; 2. Air intake; 3. Venturi; 4. Starter jet 5. Float chamber; 6. Atomizer

7. Fuel valve; 8. Needle; 9. Throttle valve; 10. Float chamber air intake; II. Fuel connection; 12. Idle mixture adjusting screw;

13. Throttle valve adjusting screw; 14. Float; 15. Idle emulsion tube, 16. Idle jet; 17. Main jet.

1. Air intake

5. Main jet

9. Idle Mixture adjusting Screw 10. Starter jet 11. Idle jet 12. Float chamber vent

13. Fuel Inlet Banjo Union 14. Needle Valve 15. Float 16. Float chamber

2. Throttle valve 3. Tapered Needle 4. Atomizer and Needle jet

6. Starting device 7. Venturi 8. Idle Speed Adjusting Screw

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Material of Motorcycle Carburetor:

There are three main materials of which carburetors are made: cast iron, zinc and aluminum. Starting in the 30s, cast iron started to be replaced by zinc and in the late 50s, aluminum replaced lot (but not all) zinc. Cast iron is much heavier and expensive than aluminum. Aluminum also has better thermal conductivity than cast iron. Zinc is easier to cast than Aluminum but its main disadvantage is that it produces white rust with air and water. Aluminum alloys are used for the manufacturing of motorcycle carburetor because of:

Low density Good corrosion resistance High thermal and electrical conductivity High dimensional stability Relatively easy to cast

All the setting parts such as the jets, atomizers, needle-valve seats, etc are made of brass.

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Manufacturing of motorcycle carburetor:

Flow process chart for Manufacturing of Carburetor

Aluminum die casting is used to manufacture the main structure body of Motorcycle carburetor. This whole process is automated.

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Aluminum die casting Since Aluminum has high melting temperature therefore a cold chamber die casting machine is used for manufacturing of motorcycle carburetor. Process of die casting: The process cycle for die casting consists of four main stages, which are explained below. 1. Clamping The first step is the preparation and clamping of the two halves of the die. Sufficient force must be applied to the die to keep it securely closed while the metal is injected. 2. Injection The molten metal is heated to 700 degree Celsius and is ladled into a chamber. It is then injected into the die through chamber at high pressure. Typical injection pressure ranges from 1,000 to 20,000 psi. This pressure holds the molten metal in the dies during solidification. 3. Cooling The molten metal that is injected solidifies in the die cavity. High pressure is maintained until the metal completely solidifies and final casting is formed. 4. Ejection After the predetermined cooling time has passed, the die halves can be opened and an ejection mechanism can push the casting out of the die cavity. 5. Trimming During cooling, the material in the channels of the die will solidify attached to the casting. This excess material must be trimmed from the casting either manually via cutting or sawing, or using a trimming press. After the castings have had time to cool they are placed into a heat treatment plant overnight. This process tempers the casting and removes porosity from cast parts After it is removed from the heat treatment the casting has its runner removed.

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Cold chamber machine open:

Cold chamber machine closed:

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Pin Boring:
In this process the casting is machined on the base to allow placement of the casting in other machines. This is carried out on a simple lathe.

CNC Turning
Turning of the casting is carried out on CNC (Computer Numeric Control) machinery. This equipment is the most accurate and fastest available for this application with very tight tolerances and extremely fast spindle speeds. The castings are placed in the chuck and the lathe is then started and the machining cycle begun. This cycle is programmed into the lathe in a basic language called G-Code (this code is not the only one available). G-Code has basic commands to tell the lathe to move to certain positions (X, Y, Z co-ordinates), at particular spindle speeds (e.g. S2500 means spindle speed 2500rpm), at particular feed rates (e.g. G01; rapid traverse) and other commands such as M01 (repeat programmed) and others. After the carburetor is machined it is removed from the lathe and the part number stamped on the carburetor.

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Grinding:
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool. It is done for fine finishes and accuracy of dimensions.

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Reaming:
Final machining process for the carburetor is that of reaming. Reaming is a process of improving the quality of already drilled holes by means of cutting tools called reamer. It is done to achieve the surface finish and sizes required. It is performed on drilling press. The difference in geometry between a reamer and a twist drill is: The reamer contains four to eight straight or helical flutes, respectively cutting edges. The tip is very short and does not contain any cutting edges.

Die Casting Tooling

Dies are made of two sections: The fixed die half, also known as the cover half, and the ejector dies half which is movable in order for the castings to be taken out. The sides of the die fold together and close like a book and are securely kept together by locking pins. Ejector pins are used to help remove the casted part. Located on the inner side of the two folding sections are negative reliefs of the metal part that is going to be made. On the cover half there are open holes called sprue holes and this is where the molted metal is poured into the die until it fills all of the nooks and crannies of the cavity on the inside of the mold. The ejector half contains passageways called runners and inlets called gates. These depressions in the die route the molten metal and force it to move into the hollow cavity of the mold. There are also openings in the dies for coolant and lubricants to be added. Lubricants are necessary as they allow the cooled product to be easily removed.

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How Dies Are Made

Dies for aluminum casting are made by creating a model of the part to be manufactured and then enveloping it with aluminum and allowing it to cool. When the aluminum is removed, it contains the cavity where the product will be formed. Dies can be made via squeeze casting, where a molten metal alloy is created at a very high pressure to make dense, high-quality, heat-treatable components. Semi-solid molding uses semi-solid billets to make a die that is heat treatable and has a low porosity. The surface of the pieces made will it have a smooth, clean-looking appearance. Cold chamber die assembly:

Die assembly Closed (Cold chamber)

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Means of serving market:

Configure to order:

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Equipment Layout: Equipment layout for motorcycle carburetor is Job shop as it is machined using different CNC machines, drills and finally screwed. Material cost
The material cost is determined by the weight of material that is required and the unit price of that material. Weight of motorcycle carburetor = 0.5 kg Cost of material being used = 2.026 USD/kg Hence total material cost = 1.013 USD

Production cost:
The production cost is primarily calculated from the hourly rate and the cycle time. The hourly rate is proportional to the size of the die casting machine being used. Die casting machines are typically referred to by the tonnage of the clamping force they provide. The required clamping force is determined by the projected area of the part and the pressure with which the molten metal is injected. Therefore, a larger part will require a larger clamping force, and hence a more expensive machine. The cycle time can be broken down into the injection time, cooling time, and resetting time. Cycle time for Aluminum die casting is around 20 seconds and clamping force required is 100 tons. For Aluminum cold chamber die casting machine Rated cycles per hour = 30 kW/40 hp. Electricity cost per kWH = 0.16 USD (In Pakistan) Hence each carburetor would cost around 5 USD

Tooling cost:
The tooling cost has two main components - the die set and the machining of the cavities. The cost of all the machinery including lathe machines, moulds and die casting machine would be around 20,000 USD.

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Each machine can produce approx 1000 pieces. Hence cost of one piece = 20 USD Total cost = material cost + production cost + tooling cost = 26 USD.

Conclusion:
Carburetors are cheap and easy to understand. Although some newer motorcycle models take advantage of advanced fuel injection systems, most still use the older style of mixing fuel and air into the combustion chambers through a carburetor. Motorcycles cannot run without this critical piece of equipment, so it is important to understand how it works and what maintenance is required to keep it running properly

Reference:
http://www.ehow.com/list_7330964_aluminum-die-casting-components.html#ixzz1qWlkO59A http://msmedi-agartala.nic.in/AluminumPressureDieCasting.html http://www.ehow.com/list_7330964_aluminum-die-casting-components.html#ixzz1qUOETmom http://www.seekpart.com/company/4119/products/2010622172851404.html http://www.ehow.com/how-does_5412773_motorcycle-carburetors-work.html#ixzz1qP5A9fEn http://www.custompartnet.com/wu/die-casting http://www.ehow.com/about_4728195_motorcycle-carburetor-basics.html#ixzz1qP3GLguh

http://www.ehow.com/about_5468040_history-carburetors.html#ixzz1qNssosVo
http://EzineArticles.com/302170 http://www.enotes.com/motorcycle-reference/motorcycle http://www.ehow.com/list_7330964_aluminum-die-casting-components.html http://ezinearticles.com/?Carburetors&id=125470 http://www.freepatentsonline.com/EP0367733.html http://www.ehow.com/about_4728195_motorcycle-carburetor-basics.html#ixzz1qbHJ7KkJ