Training Report

STUDY OF PISTON MANUFACTURING AND COMPLETION OF A PROJECT ON"UNDERSTANDINNG PISTON MANUFACTURINNG PROCESS " IN PISTON PLANT

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CERTIFICATE

This is to certify that Sambhav Jain, student of Bachelor of Technology in

Mechanical Engineering from Delhi Technological University has done a six weeks

industrial training at piston plant under my guidance and his performance has been

satisfactory throughout the training period.

Mr. Sanjeev Joshi

(Piston Plant)

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ACKNOWLEDGEMENT

I would like to acknowledge and extend my heartfelt gratitude to Mr Sanjeev Joshi,

for his guidance and help. His rich experience, cooperation and support have been a

great motivation for me to complete my industrial training. I also wish to express my

gratitude to Mr. Puranjay and all the staff of Line 17, Piston Plant for their help so

far in my training.

I further undertake that the work presented in this report has not been submitted

elsewhere.

Sambhav Jain

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Shriram pistons & rings Ltd. (SPRL) is on of the largest & most sophisticated

manufacturers of precision auto- mobile components such as pistons, piston rings,

pistons pins & engine valve in India.

The products are sold under brand name ‘USHA/SPR’ .

SPRL manufacturing unit is located at Meerut Road in Ghaziabad (25 km from Delhi).

The plant has been recognized as one of the most modern & sophisticated plants in

north India in the field of automobile the production capacity of plant.

The plant has been recognized as one of the most modern & sophisticated plants in

north India in the field of automobile the production capacity of plant.

Exports sales are of RS. 170cr. The year 2010-11.

Total area covered by the factory is 27acres.

The factory has manufacturing facilities for Piston, Ring, Pins, and Engine Valves.

Total strength of the company is 5230 nos. consisting of officers, staff, workers.

The turnover/sales for the year 2013-2014 is RS. 1200cr.

The company is exporting to more than 35 countries

.PRODUTION CAPACITY OF PLANT

Pistons 14.0 million per year. Pins 11.3million per year. Rings 70.7 million per year.

Engine valves 27.02 million per year.

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SPR received the ISO – 9001 certificate from RWTUV, Germany in 1994. Technology from

the collaborators was supplemented with in-house efforts and by implementing world-

class practices.

The company received QS-9000 certificate from TUV, Germany in the year 1999.

The company received ISO-14001 certificate in the year 2001

SPR received the TS-16949 Certificate in the year 2003.

The company received OHSAS – 18001 certificate in the year2003.

Best foundry awards from institute of Indian Foundry men in the year 2003.

Green rating awards by CII, U.P Pollution Board& World bank in 2004.

The company received TPM excellence award in the year 2004.

Excellence award in Export by Government of India.

The company received recognition award by Government of India for in House R. & D.

Received star Performer(IC Piston engine & parts) award form engineering Export

promotion Council(EEPC) India.

Received silver award-Quality & Bronze award-Spares form HONDA Siel Card(I) Ltd. In

2007.

Received Diamond award- Overall best performance in QCDDM, Outstanding

performance in cost, Bronze award for delivery, Gold award for 5s from Honda Siel

Card (I) Ltd. In 2006.

SPRL has received the Best vendor awards from Maruti Suzuki for 4 consecutive times, best

supplier performance awards from Tata Cummins Ltd for 3 consecutive years, And has self

certified status with most of the OEMs.

Excellence award in productivity by ACMA in 2007-2008.

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Excellence award I quality by Honda Scooters and Motors Limited, Honda Siel and ACMA in

2007-2008.

Excellence award in Technology by ACMA in2007-08.

Excellence award I quality by Honda Scooters and Motors Limited, Honda Siel and ACMA

in 2007-2008.

Excellence award in Technology by ACMA in2007-08

M/S Kolbenschmidt, Germany to produce pistons

M/S Riken corporation, japan for piston Rings

M/S Fyji Oozx, Japan for the manufacture of engine valves.

M/S Honda foundry, Japan of technical support

M/S Hero Honda, Kinetic Honda, & Shriram Honda.

The company supplies it products to several Original Equipment Manufacturers (OEMs).

Such as Defense Vehicle Factories, Ashok Leyland, Tata Cummins, Maruti Suzuki, Mahindra,

Eicher Tractors, DTL(swaraj), Kirloskar Oil Engines, Bajaj AutoHonda Cars, Sudram Claylon,

Honda Scooter.

Shriram pistons & Rings Ltd. Quality is integral part of whatever we do, which is reflected

in the company’s quality policy.

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T:-TOTAL Maximization of Total efficiency. Entire life cycle of production system. Cover all departments. Participation of all Employees.

P:-PRODUCTIVE

Pursue the maximization of efficiency of the production system by making all losses zero.

Zero Accidents, Zero defects, Zero Breakdowns are real meaning of maximization of efficiency.

M:-MAINTENANCE

Maintenance Cover the entire life cycle of the Production system. IT refers to maintenance of individual process, plant & Production management systems.

TPM –POLICY

“ZERO FAILURE” , “ZERO DEEFECT” , “ZERO ACCIDENT”, Through introduction of TPM with participation.

Maximum profit through improvement of overall equipment efficiency, production in cost & increase in customer satisfaction.

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Continuous improvement.

Technology development.

Organizational and Personnel development.

Cost Reduction efforts.

Effective use of all resources.

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TOTAL CUTOMER SATISFACTION THROUGH QUALITYMANAGEMENT AND CONTINUOUS IMPROVEMENT

Organization which is sensitive & interactive to the needs of customer.

Work to international norms of Quality & Management.

The company has successfully practiced the best work ethics & technology along with the TPM & kaizen approach & harmony through teamwork.

Continuous upgrading of quality & process to meet changing of customer.

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Description of a general automobile piston

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PISTON

A cylindrical, hollow aluminum or iron part, closed on top and open at the bottom, fitting closely within the engine cylinder or sleeve and capable of being driven alternately up and down in the cylinder. The piston transmits the force of expanding combustion gases through the piston pin to the connecting rod and crankshaft throws. The piston serves as a carrier for the piston rings

Aluminium alloys are the preferred material for pistons both in gasoline and diesel engines due to their specific characteristics:- low density, high thermal conductivity, easy machinability, high reliability and very good recycling characteristics. Proper control of the chemical composition, processing conditions and final heat treatment results in a micro structure which ensures the required mechanical and thermal performance, in particular the high thermal fatigue resistance.

The standard material for piston is Al-12%Si alloy containing in addition approximately 1% each of Cu, Ni and Mg.

Following are the standard Piston terminologies:-

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A) LAND

That part of the piston above the top ring or between ring grooves. The lands confine and support the piston rings in their grooves.

B) HEAT DAM

A narrow groove cut in the top land of some pistons to reduce heat flow to the top ring groove. This groove fills with carbon during engine operation and reduces heat flow to the top ring.

C) COMPRESSION DISTANCE (or height)

The distance from the center of the pin hole to the top of the piston. where grooves are machined.

D) RING BELT

That area between the top of the piston and the pin hole for the installation of piston rings.

E) PISTON HEAD

The top piston surface against which the combustion gases exert pressure. The

piston head may be flat, concave, convex or of irregular shape.

F) PISTON PINS (Wrist pins or gudgeon pins)

Connections between the upper end of the connecting rod and the piston. Pins may be held in one of three ways:

1. Anchored in the piston with the bushing in the upper end of the connecting rod oscillating on the pin.

2. Clamped in the rod with the pin oscillating in the piston.

3. Full floating in both connecting rod and piston with lock rings or other devices preventing the pin from contacting the cylinder wall.

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G) SKIRT

That part of the piston located between the first ring groove above the pin hole, and the bottom (open end) of the piston. The skirt forms a bearing area in contact with the cylinder wall.

H) PIN HOLE

An opening through the piston skirt to carry the piston pin.

I) MAJOR THRUST FACE

That portion of the piston skirt which carries the greatest thrust load. This is on the right side when viewing the engine from the flywheel end with the crankshaft rotating counterclockwise.

J) MINOR THRUST FACE

That portion of the piston skirt which is opposite the major thrust face.

K) OIL RING GROOVE

A groove cut into the piston around its circumference, at the bottom of the ring belt or at the lower end of piston skirt. Oil ring grooves are usually wider than compression ring grooves and generally have holes or slots through the bottom of the groove for oil drainage to the interior of the piston.

L) COMPRESSION RING GROOVE

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A groove cut into the piston around its circumference, in the upper part of the ring belt. The depth of groove varies depending on piston size and types of rings used.

M) SCUFF BAND

A narrow raised band or bands machined on the top land of some pistons to reduce the possibility of scuffing.

N) GROOVE DEPTH

The distance from the cylinder wall to the bottom of the ring groove with the piston centered in the cylinder.

O) GROOVE ROOT DIAMETER

Diameter of the piston measured at the bottom of the groove. The root diameter of each groove on any given piston may differ, depending on the type of ring to be installed.

P) LAND DIAMETER

Diameter of the land being measured. In some piston designs all lands are equal diameter. In others they increase from top to bottom.

Q) SKIRT GROOVE

A groove cut into the piston around its circumference below the pin hole to carry an oil ring.

R) OFFSET PIN HOLE

On some pistons the pin hole is offset to one side of the piston centerline.

S) TOP GROOVE SPACER14

Badly worn top grooves must be re machined before installation of new rings. A steel spacer is installed above the ring in a reconditioned groove to reduce the side clearance to the recommended dimension.

PISTON SKIRT TAPER - The difference between the diameter of the piston at the top of the skirt and at the bottom of the skirt with the diameters being measured in the thrust direction.

PISTON CAM - The circumferential shape in which a piston skirt is manufactured to provide proper cylinder contact and running clearance under all normal conditions of temperature and load.

CAST-IN GROOVE INSERT-A steel or cast iron insert, in an aluminum piston, either chemically or mechanically bonded during the manufacturing process, into which the top groove is machined to provide a longer wearing surface for the top ring

PISTON PRODUCTION

Piston in foundry shop:- The pistons are first produce in the foundry shop from the

Molten metal in the form of rough piston whose diameter is larger than finished

product

The Piston from foundry shop undergoes the following process to get the final

product :-

1. Rough turning

Rough turning operation is the initial turning operation, it may or may not be required for a given type of piston

2. Locating seat turning

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This is generally the first and one of the most important process in the line , locating

seat is the base on which further operations are performed on the piston ,so it

should be of maximum accuracy

3. Pre pre boring

This is the process in which ring bore are first enlarged before feeding it to pre-

boring machine

4. Pre boring, Enlargement & Circlip grooving

This is a major step in the manufacturing of piston the piston after pre pre boring is fed into the pre boring machine to enlarge the bore before final boring , circlips are also made during this step.

5. Broaching

Broaching is made for providing lubrication between the pinbore and the gudgeon

pin, it is done using a broaching tool.

6. Oil hole drilling

Oil holes are drilled to provide lubrication to the inside part of the piston during engine running, oil holes are drilled after the broaching operation.

7. Angular drilling

Angular holes are drilled in a separate process.

8. Pin Boss drilling

9. Pre Grooving & Cavity Turning including fine facing.

A piston is not completely vertical in height, some mount of curve is given so as to facilitate the return stroke, this type of facing is performed on a fine facing machine Cavity turning and pre grooving are done for making ring sockets

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10. Finish Oval Turning

A piston is not completely circular in cross section, some type of ovality is given , this is done on a ova turning machine , in an oval turning machine the X,Y,&Z feeds can be provided independently .

11. Finish grooving & groove chamfering

This is the final grooving process in which ring grooves are cut.

12. Fine Boring

The fine boring operation is the last machining opertation performed , it is done on

a fine boring machine

13. Washing

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Washing of piston is a long process in which it goes through foolowing steps:-

14. Visual Inspection

Visual inspection is performed to check for surface and other defects in the

machining .

15. Tin Plating

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According to the demand of the customer the pistons are send for tin plating. In electroplating, an ionic metal is supplied with electrons to form a non-ionic coating on a substrate. A common system involves a chemical solution with the ionic form of the metal, an anode (positively charged) which may consist of the metal being plated (a soluble anode) or an insoluble anode (usually carbon, platinum, titanium, lead, or steel), and finally, a cathode (negatively charged) where electrons are supplied to produce a film of non-ionic metal.

LAYOUT OF LINE 17

for M-Ford1.6Lsigma Exp

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Production optimization techniques employed

Poka Yoke

Poka-yoke is a Japanese term that means "mistake-proofing". A poka-yoke is any mechanism in a lean manufacturing process that helps an equipment operator avoid mistakes. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.

Poka yoke was provide on the following machines:-

1. To check pre pre boring operation before boring operation.

2. For prevention of variation between enlargement diameter and pre bore diameter.

3. For prevention of wrong loading of piston.

4. To check compression height, pin bore diameter, groove diameter, pin bore squareness, major outside diameter.

5. To check for oil hole drilling.

6. To check for drilling pin boss.

7. To check for missing slot in pin bore.

In process inspection

Apart from utilizing poka yoke individual inspection apparatus is provided to each

worker so that he can inspect and correct any irregularities in the machining, also

rejection chart and production charts are used to measure and reduce rejections

and optimize production.

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CONCLUSION

I have done 6 weeks training in Shriram Piston and Rings Limited

Ghaziabad, with my experience I can say that this opportunity has

proved a boon for me and it have really helped me to understand

industrial ethics and professional work culture. Highly automatic

environment of industry have really helped in

Understanding concept of CNC machines.

I completed my training in piston plant in which I studied P.O.S.

(production operation sequence) for many piston models and I was

also assigned a project Understanding Piston Manufacturing Process.

Finally I can conclude that this training will be really helpful for me in

developing me as an engineer and explore my potential.

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