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Mayank
Mayank
BY: MAYANK
SRIVASTAVA
ROLL NO :1503240095
Company profile
Shriram pistons & rings Ltd.(SPRL) is one of the largest
& most sophisticated manufacturers of precision
automobile components such as pistons, piston rings,
piston pins, engine valves in India.
• 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
•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 ) THEROD
•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.
• 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 apiston.
• This process causes the piston to become so hot, that it needs an hour to
cool.
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 also drilled.
5) RingGrooves
• 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 finalform.
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.
•Ahuman 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.