Arjstmt 01 004

Advanced Research Journals of Science and Technology

ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY

(ARJST)

MULTI CAVITY DIE PREPARATION AND MANUFACTURING PROCESS OF DIESEL ENGINE PISTON

2349-3636

Jiang Guo He1,Yanxia Wang,2, 1 Research Scholar, Department of Mechanical Engineering,Shanghai Maritime University Shanghai- China.

2 Professor , Department of Mechanical Engineering, Shanghai Maritime University Shanghai- China.

Abstract In our project a piston for 1300cc diesel engine car will be designed using empirical formulas for the material Cast Iron.

A 2D drawing is created from the calculations. The piston is modeled from 2D drawing using CREO parametric (Pro/ Engineer) software.

Generally manufacturing process for pistons is casting. So we have to design a die tool for the piston manufacturing.

Designing of casting tool die for four cavities will be done. Core and Cavity will be extracted and total die will be designed as per the standards. CNC program will be generated for both core and cavity.

A prototype of piston is to be manufactured.

Modeling, core – cavity extraction, die design and CNC program generation is done in CREO parametric (Pro/Engineer) software. *Corresponding Author: Jiang Guo He , Research Scholar, Department of Mechanical Engineering, Shanghai Maritime University Shanghai- China.

Published: September 10, 2014 Review Type: peer reviewed Volume: I, Issue : II Citation: Jiang Guo He,Research Scholar (2014) MULTI CAVITY DIE PREPARATION AND MANUFACTURING PROCESS OF DIESEL ENGINE PISTON

INTRODUCTION TO PISTON In every engine, piston plays an important role in working and producing results. Piston forms a guide and bearing for the small end of connecting rod and also transmits the force of explosion in the cylinder, to the crank shaft through connecting rod.

known as skirt. There are grooves made to accommodate the compression rings and oil rings. The groove, made for oil ring, is wider and deeper than the grooves made for compression ring. The oil ring scraps the excess oil which flows into the piston interior through the oil return holes and thus avoiding reaching the combustion chamber but helps to lubricate the gudgeon pin to some extent.

In some designs the oil ring is provided below the gudgeon pin boss .The space between the grooves are called as lands.

The diameter of piston always kept smaller than that of cylinder because the piston reaches a temperature higher than cylinder wall and expands during engine operation.

The space between the cylinder wall and piston is known as piston clearance. The diameter of the piston at crown is slightly less than at the skirt due to variation in the operating temperatures. Again the skirt itself is also slightly tapered to allow for unequal expansion due to temperature difference as we move vertically along the skirt the working temperature is not uniform but slightly decrease.

The piston is the single, most active and very critical component of the automotive engine. The Piston is one of the most crucial, but very much behind-the-stage parts of the engine which does the critical work of passing on the energy derived from the combustion within the combustion chamber to the crankshaft. Simply said, it carries the force of explosion of the combustion process to the crankshaft.

Apart from the critical job that it does above, there are certain other functions that a piston invariably does -- It forms a sort of a seal between the combustion chambers formed within the cylinders and the crankcase. The pistons do not let the high pressure mixture from the combustion chambers over to the crankcase.

Construction of Piston Its top known by many names such as crown, head or ceiling and thicker than bottom portion. Bottom portion is

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Advanced Research Journals of Science and Technology

INTRODUCTION TO CAD Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use of computer technology for the process of design and designdocumentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provide the user with input-tools for the purpose of streamlining design processes; drafting, documentation, and manufacturing processes. CADD output is often in the form of electronic files for print or machining operations. The development of CADD-based software is in direct correlation with the processes it seeks to economize; industry-based software (construction, manufacturing, etc.) typically uses vector-based (linear) environments whereas graphic-based software utilizes rasterbased (pixelated) environments.

3D MODEL PREPARATION

Two variants are pore-free die casting, which is used to eliminate gas porosity defects; and direct injection die casting, which is used with zinc castings to reduce scrap and increase yield.

Cast metals The main die casting alloys are: zinc, aluminium, magnesium, copper, lead, and tin; although uncommon, ferrous die casting is possible. Specific dies casting alloys include: ZAMAK; zinc aluminium; aluminium to, e.g. The Aluminum Association (AA) standards: AA 380, AA 384, AA 386, AA 390; and AZ91D magnesium. The following is a summary of the advantages of each alloy: • Zinc: the easiest alloy to cast; high ductility; high impact strength; easily plated; economical for small parts; promotes long die life.

• Aluminium: lightweight; high dimensional stability for complex shapes and thin walls; good corrosion resistance; good mechanical properties; high thermal and electrical conductivity; retains strength at high temperatures.

• Magnesium: the easiest alloy to machine; excellent strength-to-weight ratio; lightest alloy commonly die cast.

• Copper: high hardness; high corrosion resistance; highest mechanical properties of alloys die cast; excellent wear resistance; excellent dimensional stability; strength approaching that of steel parts.

• Lead and tin: high density; extremely close dimensional accuracy; used for special forms of corrosion resistance.

Such alloys are not used in foodservice applications for public health reasons.

Hot-chamber

DIE CASTING

Cold-chamber

Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity, which is machined into two hardened tool steel dies. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter and tin based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.

The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small to medium sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.

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Advanced Research Journals of Science and Technology

Core and Cavity

MULTY CAVITY

Molds separate into at least two halves (called the core and the cavity) to permit the part to be extracted. In general the shape of a part must not cause it to be locked into the mold. For example, sides of objects typically cannot be parallel with the direction of draw (the direction in which the core and cavity separate from each other). They are angled slightly (draft), and examination of most plastic household objects will reveal this. Parts that are "bucketlike" tend to shrink onto the core while cooling, and after the cavity is pulled away. Pins are the most popular method of removal from the core, but air ejection, and stripper plates can also be used depending on the application.

Most ejection plates are found on the moving half of the tool, but they can be placed on the fixed half.

CORE & CAVITY PREPARATION OF MODEL

MULTY CORE

Parting Surface

DIE ASSEMBLEY CAVITY

INTRODUCTION TO MANUFACTURING CORE

The manufacturing of various products is done at different scales ranging from humble domestic production of say candlesticks to the manufacturing of huge machines including ships, aeroplanes and so forth. The word manufacturing technology is mainly used for the latter range of the spectrum of manufacturing, and refers to the commercial industrial production of goods for sale and consumption with the help of gadgets and advanced machine tools. Industrial production lines involve changing the shape, form and/or composition of the initial products known as raw materials into products fit for final use known as finished products.

Manufacturing Technology The subject of manufacturing technology is very vast and includes various types of machines tools required to manufacture finished products which range from simple handheld tools, lathe machines, grinders, milling machines to highly versatile and complicated computerised numerical control or CNC machines and so forth. Of course it also

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Advanced Research Journals of Science and Technology

involves several different techniques of manufacturing which can be a subject matter of different details discussion and some of these include casting, forging, alloying, welding, soldering, brazing etc. each of these techniques have their own advantages and limitations and are a specialized field of knowledge in their own right.

G03X87.144Y-183.053I-14.019J0.

G01Z0.

M30 %

PROCEDURE OF MANUFACTURING

PLAY PATH

FINISHING

CAVITY ROUGHING

PLAYPATH

VERICUT

ROUGHING PROGRAM % G71 O0001 N0010T1M06 S5000M03 G00X5.Y-5.

G43Z0.H01 G01Z-5.F200.

X201.177 Y-9.914 G01Z0.

G00X87.144 Z-49.007 G01Z-55.01

VERICUT

FINISHING PROGRAM % G71 O0002 N0010T1M06 S5000M03 G00X5.Y-5.

G43Z0.H01 G01Z-5.F200.

X201.177 Y-9.914 X5.

Y-14.828 X201.177 Y-19.742 X5.

Z0.

M30 % Conclusion: This project work deals with “Multy cavity die preparation and manufacturing process of diesel engine piston".

In the first step data collection and inputs are collected for the design of piston for diesel engine.

In the next step design calculations are done using mathematical formulae’s from the calculations piston dimensions are required.

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Advanced Research Journals of Science and Technology

A 3d model was generated using above calculations.

Tool design calculations are done to prepare the die assembly.

Core and cavity inserts are prepared using manufacturing model in pro- engineer.

Mould tool parts are prepared and assembled withdrew set.

CNC program was generated for both core and cavity inserts.

By observing above information it concludes that using above process piston manufacturing can be done with multy cavities so it increases the production rate which in terms effect’s on reduction of cost of part production.

References [1] Richard Mittler and Albin Mierbach, “Proceedings of the ASME Internal Combustion Engine Division 2009 Spring Technical Conference”, ICES2009 May 3-6, 2009, Milwaukee, Wisconsin, USA [2] P.Gustof, A.Hornik, “International Journal of Achievements in Materials and Manufacturing Engineering” ,Vol. 35 Issue 2 August 2009.

[3] Tulus, Ariffin, A. K., Abdullah, S. and Muhamad. N. “Proceedings of the 2nd IMT-GT Regional Conference Of Mathematics, Statistics And Applications University Sains Malaysia”,June 13-15,2006.

[4] Sanjay Shrivastva,Kamal Shrivastava, Rahul S. Sharma and K Hans Raj, “Journal of scientific &Industrial Research”, vol .63, December 2004,pp 997-1005.

[5] Gunter Knoll, Adrian Rienäcker, Jochen Lang, “Lehrstuhl für Maschinenelemente und Tribologie Universität Gh Kassel Germany”, McGraw-Hill Book Company, p. 700 f.

[6] Thet T. Mon, Rizalman Mamat, Nazri Kamsah, Member, IAENG, ” Proceedings of the World Congress on Engineering 2011 Vol III WCE 2011, July 6 - 8, 2011, London, U.K. [7] E. Abu-Nada, I. Al-Hinti, A. Al-Sarkhi, B. Akash “Department of Mechanical Engineering, Hashemite University, Zarqa 13115, Jordan”, Institution of Mechanical Engineers, London, pp. 133–145.

[8] Ashwinkumar S. Dhoble, R. P. Sharma, “R& D Centre, Mahindra & Mahindra Ltd.,Nashik”, SAE Paper 930797 (1993).

AUTHOR Jiang Guo He, Research Scholar, Department of Mechanical Engineering, Shanghai Maritime University Shanghai- China.

Yanxia Wang, Professor, Department of Mechanical Engineering, Shanghai Maritime University Shanghai- China.

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