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8/14/2019 work shp training

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About The Company:

In The Last Summer, I Choose To Do My Summer Practice, So I Did It In

Iqab Fraij & Partners Company, This Company Is Steel Specialist.

The Company Location Is In North Marka Amman Jordan , Also There

Were Two Sections In The Company, First One Was For Turning Steel Sheets To

Make Large Pipes, Where They Used Two Revolving Wheel To Turn The Sheets.

The Second One , Where I Did My Training, Was The Cylinder Liner

Section, There Were Only One Engineer And All The Others Were Workers, The

Engineer Position Was The Production Engineer And Actually He Is One From

The Owners Of The Company.

In This Part Of The Factory There Was Two Department, First One The

Oven Part, Where They Reused The Remained Material Again, The Other One

Was The Lathe Part.

In Lathe Part, There Was:

1-Two External Lathing Machines.

2-Two Internal Lathing Machines.

3-3CNC Lathing Machines.

4-One Machine To Cut The Material By Lathing.

5-One Milling Machine.

6-One Grinding Machine.

What Is Cylinder Liner?


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Figure 1 : Cylinder Liner(Sleeve) & Piston & Piston Rings

Cylinder Liner Or Cylinder Sleeve Is A Cylindrical Part Made To

Be Fit In The Engine To Form The Cylinder & It Is One Of The Most

Necessary Parts To Make Up The Interior Of The Engine, ActuallyEach Engine Has Its Own Cylinder Liner Dimensions.

Function Of Cylinder Liner:

1-Formation Of Sliding Surface-:

Cylinder Sleeve Serving As An Inner Wall Of Cylinder ,

Forming A Sliding Surface For Piston Rings While Keeping The

Lubricant In, The Most Important Function Is The Excellent

Characteristic As Sliding Surface & These Four Important

Points:

a-High Anti-Galling Properties.

b-Less Wear On The Cylinder Liner It Self.

c-Less Wear On The Partner Piston Ring.

d-Less Consumption Of Lubricant.

1-Heat Transfer:

Figure 2 : Impact Inside Cylinder

Cylinder Liner Receives Consumption Heat Through Piston

& Piston Rings & Transmits The Heat To The Coolant.

2-Compression Gas Sealing:


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The Cylinder Liner Prevents The Compressed Gas And

Consumption Gas From Escaping Outside.

It Is Important That The Cylinder Sleeve Which Is Hard To

Transform By High Pressure & Temperature In The Cylinder.

The Cylinder Wall Is Under High Condition Of Pressure &Temperature ,With Piston & Piston Ring Sliding At High Speeds, So

In Particular ,Since Longer Service Life Required

For The Engines For Trucks And Busses , The Cast Iron Cylinder

Which Have Excellent Wear-Resistance Properties are Only Used ForCylinder Parts.

Also, For Lighter Engines, Material Shifting From Cast Iron To

Aluminum Alloys Are Used , But As The Sliding For The Inner

Cylinder, The Direct Sliding Motion Of Aluminum Alloys Has

Drawbacks In Deformation During Operation & Wear-Resistance. For

That Reason ; Cast Iron Used In The Most Cases.


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How To Make Cylinder Liner:

Cylinder Liner Usually Made From Cast Iron, Cast Iron Have A

Good Properties Such As Hardness & Thermal Conductivity ,

Expansion Coefficient & Has Excellent Wear Resistance.

Table 1 : Hardness For Some Materials

Table 2 : Expansion Coefficient & Thermal Conductivity

To Make A Cylinder Liner There Are Many Steps In Two

Sections, Oven Section & Lathe Section.

In Oven Section, They Melt The Remain Cast Iron From

Last Operation, In Order To Reuse It Again, They Use AnElectrical Oven, By The Way We Know That When We Melt


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The Material, It Loses Some Of Its Properties, So In Order To

Solve This Issue They Add Some Other Materials, Such As :

Si (Silicon) ,C (Carbon) ,Mg (Magnesium) ,C (Chromium) ,

The Temperature In Side The Oven Is 14500c & The Oven

Consumes 250 Kw/H.

Figure 3: Spoiled Cylinder

After That & While The Compound Is At Liquid StateThey Reshape It To The Cylinder Form. Then Leave It For

Cooling.

The They Move It To The Other Section, The Lathe

Section.

In This Section There Are Many Steps,(The Steps Are In

Order(


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1-External Lathing:They Put The Spoiled Cylinder

There, And Stare The Lathing, Because The Spoiled

Cylinder Has Very Bad Surface, Here They Made A

Step To Reshape It, In The Factory There Was Two

External Lathing Machines.

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2-Internal Lathing: Internal Lathing Is To Get Better

Surface Than The Spoiled One. There Was Two

Internal Lathing Machines.


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3-CNC Lathe: CNC Machine Is Always The Most

Accurate Machine, And Because The Cylinder Liner Is

Important Part In The Engine, It Has To Be Built In

Very Accurate Tolerances, So They Are Using TheCNC Machines, There Were Three CNC Machines

There But Unfortunately Only One Was Working.

Figure 5: CNC Machine

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The Cylinders To The Grinding Machine To Obtain

The Geometry Of The Parts.

Figure 6: Grinding Machine

5-Honing Machine: They Use This Machine To ObtainThe Inside Surface Of The Cylinder As Smooth, It

Take 1mm From The Inside Thickness.


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Figure 7 : Honing

Figure 8: Before CNC Machine

Conclusion:In That Period, I Have Been Saw The Lathing & Grinding Processes,

And If I Add What I Saw To What I Have Learned In Manufacturing

210, So Now I Have A Nice Vision About These Processes.

Also, Now I Know How To Make One Of The Most Important Function

In The Engines, Also I Become Familiar With Some New Advices

That I Have Never Hear About It Before, Such As

Micrometer(Micrometer Screw Gauge) & The Depth One, Also I

Learned How To Use Them.


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Figure 9 : Micrometer & Depth Micrometer

AppendixFigure 1 : Cylinder Liner(Sleeve) & Piston &

Piston Rings : Page 1

Figure 2 : Impact Inside Cylinder : Page 2

Table 1 : Hardness For Some Materials : Page 4


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Table 2 : Expansion Coefficient & Thermal

Conductivity : Page 4

Figure 3: Spoiled Cylinder : Page 5

Figure 4: External Lathe Machine : Page 6

Figure 5: CNC Machine : Page 7

Figure 6: Grinding Machine : Page 7

Figure 7 : Honing : Page 8

Figure 8: Before CNC Machine : Page 8

Figure 9 : Micrometer & Depth Micrometer :

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