Forming applications in Automotive industry presentation

Forming Applications in Automotive Industry

Group 6Under Supervision of: Dr.

Mohamed A. Daha

The Automotive Industry The Automotive industry is one of the largest

industries in the World

Trends compete every year for the most powerful, economic , beautiful in the market

And what define the winner is the manufacturing process behind the spinning wheels

24 December 2013

DiscussingManufacturing of Car parts

Engine

pistons

crankshaft

Connection rod

Body

chassis

doors

suspension system 

Rims

Shock Absorber

The Engine An engine is a related group of parts assembled

in a specific order , it’s designed to convert thermal energy given off by burning the fuel into a useful form.

We will just discussSome of it’s components and how it’s manufactured

Piston A solid disk or cylinder that fits inside a hollow

cylinder, and moves under pressure It’s made from cast iron or aluminum alloy It’s should be wear resistance and can take very heavy impact loading

Made: (Forging) The piston begins as a, solid aluminum rod Then after it’s been cut as slug and preheated

the slug is placed into the punch. The press applies 2,000 tons of pressure onto the

slug, forging it into the basic shape of a piston.

Crank Shaft It’s main duty Is to convert the angular motion of

the connection rod to a rotary motion to the transmit the mechanical motion.

It’s made from carbon steel alloy and the carbon percentage vary on the application of the crank shaft in different engines

Made: (open Die Forging)

Then it’s heat treatment due to residual stresses gained from forging so we make annealing process to increase ductility and reduce residual stresses

Connection Rod It’s a rod that connects from it’s upper pin the

piston and from it’s down pins the crank shaft It’s convert the Reciprocating motion of the

piston to an angular motion to the crank shaft It’s made from aluminum alloy now days to

withstand the high repeated stress (high endurance limit).

Made : (Closed Die Forging & Blanking)

First we use forging (on different steps ) to increase the mechanical properties of the rod and it’s resistance to impacts .

Then use blanking to cut the material which are not needed (scrap)

Out From the Engine

Now let’s try to see how Sheet Metal Forming Convert

The Body It consist from frame and chassis which it’s main

function to support the construction on the vehicle and give safety to it’s equipments and passengers

Safety First

Now days it’s design from weaker and lighter material

Aluminum , Magnesium WHY!!!!!!!

Chassis Automotive chassis or automobile chassis helps

keep an automobile rigid, stiff and unbending. Auto chassis ensures low levels of noise and vibrations

Chassis It used to be steel, but corrosion attacked unless

a good coating is added , then aluminum is used adding to its alloys zinc and magnesium to increase hardness and toughness, then titanium is added to alloys, and sometimes fiberglass and carbon fibers is used

Made : (Step 1)Rolling Using pinch rolling (form rolling) processes to

produce the chassis metal pars.

Made :(Step 2) (Sheet Hydro Metal forming)

Doors It's made of sheets of carbon steel.

Then the machine divide the big coil into small plates

Doors

Using deep drawing processes we produce the outer door panel

Doors

• At the next step we assemble the door frame with the inner door panel.

• Then assemble the outer door panel with the inner door panel by pressing them.

Suspension System

we need a way or a system that can dumb vibrations and stress to it’s minimum limits as possible to ensure the comfort of the passengers and safety of the vehicle

24 December 2013 Group 6

Shock Absorver A shock absorber is basically an oil pump placed

between the frame of the car and the wheels. The upper mount of the shock connects to the frame (i.e., the sprung weight), while the lower mount connects to the axle,

24 December 2013 Group 6

How it’s made Step 1 :(Tube Rolling)• At the next step we use the tube rolling processes

to produce the cylindrical shape of the tube.

• Then using a huge welding wheel we close the tube

24 December 2013 Group 6

How it’s made step 2 :(Impact Extrusion)• Using impact extrusion we compress the end of

the tube in order to make the tube hold more oil.

• Then we assemble the valve with the cylinder.

24 December 2013 Group 6

The Metal Wheels (Rims) The rim is the "outer edge of a wheel, holding

the tire". It makes up the outer circular design of the wheel on which the inside edge of the tire is mounted on vehicles such as automobiles.

Made :(Hot Forging)

Hot Forging - Takes a billet and creates metal lines through volume distribution with a hot press

Conclusion

The Metal Forming Technology (Sheet , Bulk) is one of the core manufacturing technology that have big impact on the automotive industry and all automobile manufactures every year try to come up with the best forming method to improve their design

Questions ………………………. ?

About :

Forming Applications in Automotive Industry

Group :6

Under Supervision of: Dr. Mohamed A. Daha

Mohamed Mostafa Ahmed

Mohamed Ibrahim Ahmed

Mahmoud Khairy Abd-

Elsalam

Eman Abd-Elfatah Ahmed

Takla Nabil Sawires

Beshoy Raafat Naaem

Toka Mohamed El-Sayed

Khulod Abdullah

Saleh

Mohamed Samir

Mohamed

Emad El-din Abd el

hafeiz

Team Members

Thank you for your time