UNIVERSITY OF ENGINEERING AND TECHNOLOGY

Taxila.
DEPARTMENT OF MECHANICAL ENGINEERING

End Semester Project

SUBMITTED BY:
• Syed Faiq Musharraf (20-ME-45)
• Muhammad Anax (20-ME-49)
• Saib Chaduary (20-ME-53)
• Usama Rubani (20-ME-57)
• Muhammad Ijlal Wasiq (20-ME-61)
• Faizan Hassan (20-ME-65)
• Abdul Rahman (20-ME-69)
• Shahzaib Hassan (20-ME-73)
SUBMITTED TO:
Engr. Muhammad Nouman
 Workshop Practice
End Semester Project
Fuel Tank Cover
Contents:
➢ Objective
➢ Introduction
➢ Working of a fuel tank cover
➢ Making of a fuel tank cover
➢ Operations
• Casting
• Turning and Facing
• Milling
• Filing and sanding
➢ Table of Cost
➢ Applications

Objective:
The objective of our project is that we make a fuel tank cover by casting
and performing different machining operations, for better understanding the
machining operations.

Introduction:
The fuel tank cover is a simple but important component that is found on the
vast majority of road going cars and trucks. Their purpose is simple; to prevent dirt,
debris, and dust from entering the fuel tank, as well as providing a reliable seal.

Working of a fuel tank cover:

It works by providing a reliable seal to the tank and preventing dirt, debris, and
dust from entering the fuel tank.

Making of a fuel tank cover:

A fuel tank cover is made by the process of casting; in which we pour a melted
metal in a cast mold as the shape of the cover.
Operations we applied:
We applied various operation for making of this fuel tank cover. They are given
as follows:

1. Casting:
• Casting is a process of pouring molten metal
into a mold. On cooldown the metal acquires
the shape of the mold. In our case, we are to cast
a fuel tank cover.
• We prepared the mold of the required shape by
using a split pattern of same shape as the fuel
tank cover.
• The prepared mold is the sand mold.
• Then we melted the cast iron in the furnace at
1127°-1204° C.
• After then we poured the molten metal in the mold carefully, and it is set for a day to
cool down slowly. This slow cooldown also enhances the properties of the cast iron.
• After a time lapse of one day, we opened the mold, and removed all the burned sand
from its surface by washing the casted workpiece in water. After that the final
component looks like this
2. Turning and Facing:
• Turning is the most common lathe machining operation. During the
turning process, a cutting tool removes material from the outer
diameter of a rotating workpiece. Finish turning produces a smooth
surface finish and the workpiece with final accurate dimensions.
• Facing on the lathe uses a facing tool to cut a flat surface
perpendicular to the work piece's rotational axis. A facing tool is
mounted into a tool holder that rests on the carriage of the lathe.
Facing will take the work piece down to its finished length very
accurately.
• We applied operation of turning and facing on lathe machine to bring
the cover to the required dimensions.

3. Milling:
• Milling is the process of machining using rotary cutters to remove
material by advancing a cutter into a workpiece. Milling covers a
wide variety of different operations and machines, on scales from
small individual parts to large, heavy-duty milling operations.
• We did milling operation on it so that we can make the features on
its sides.

4. Filing and Sanding:

• Filing is a material removal process in manufacturing. Filing
operations can be used on a wide range of materials as a
finishing operation. Filing helps achieve workpiece function by
removing some excess material and deburring the surface.
• Sanding serves to remove imperfections on workpiece
• After working on milling machine, we finished the workpiece
by filing and sanding down any sharp edges or sides.
• In the end, any further amendments are made to give off a finished workpiece.

After Performing the machining operations, the final shape and geometry of the
component looks like this
Table of Cost:

Material Quantity Price

Cast Iron 0.5 Kg Rs.800
Pattern 1 Rs.500
Mold 1 Rs.300
Machining Operations 5 Rs.300
Labour cost - Rs.600
Grand Total - Rs.2500

Applications:
• It is used in fuel tank of petrol engine and diesel engine as a cover, that
provide an added layer of protection to the tank.
• It is used to air tighten the fuel tank and to prevent the vaporizing the petrol
or diesel from the fuel tank
• It also used to prevent dirt, debris, and dust from entering the fuel tank, as well
as providing a reliable seal.
 Gantt Chart:
Activities Week 6 Week 7 Week 8 Week 9 Week 10
Group
selection
Project
selection
Project
Approval
Project
Study
Survey
of thing
Project
making
Project
report

THE END
 Produced By Date
20-ME-45 20-ME-49 20-ME-53 20-ME-57 20-ME-61 20-ME-65 20-ME-69 20-ME-73 03-12-2021

Workshop Practice Checked By Drawing Name Scale Unit

Semester Project Engr. Muhammad Noman Fuel Tank Cover 1:1 Millimeters