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Table of Contents Chapter 1: About the company ....................................................................................................................... 1 Introduction ..................................................................................................................................................... 2 History............................................................................................................................................................ 3 Milestones………………………………………………………………………………….4 Products…………………………………………………………………………………….5 Chapter 2: About the department ................................................................................................................... 5 Piston rings ...................................................................................................................................................... 5 1.Manufacturing Engineering group ........................................................................................................... 6 2. Large Bore Machine Shop…………………………………………………………. 3. Heat Treatment…………………………………………………………………… 4. Ring Foundry…………………………………………………………………….. 5. Besley Section………………………………………………………………….... 6. Splitting…………………………………………………………………………… 7. Plating….....……………………………………………………………………….. 8. GTP rings………..........…………………………………………………………… 9. Plane ring cell……………………………………………………………………. 10. FMTPR………………………………………………………………………….. Piston………………………………………………………………………………..... Chapter 3: Tasks performed……………………………………………………………. Observations done in FMTPR…………………………………………....……………. Physical Vapour Deposition……..............................…………………………………. Observations done in GTP line……………………………………................................ Chapter 4: Outcomes……………….........……………………………………………….

Chapter 1: About the company INTRODUCTION Federal-Mogul Goetze (India) Limited was established in 1954 as a joint venture with Goetze-Werke of Germany. Goetze-Werke of Germany is now owned by Tenneco (Federal-Mogul Corporation), a $6.3 billion global company and one of the leading manufacturers of automotive components in the world. Federal-Mogul Goetze (India) Limited is the largest manufacturer of pistons and piston rings in India. Headquartered in Lake Forest, Illinois, Tenneco (Federal-Mogul) is one of the world’s leading designers, manufacturers and marketers of Ride Performance and Clean Air products and technology solutions for diversified markets, including light vehicle, commercial truck, off-highway equipment and the aftermarket, with 2017 revenues of $9.3 billion and approximately 32,000 employees worldwide. On October 1, 2018, Tenneco completed the acquisition of Federal-Mogul, a leading global supplier to original equipment manufacturers and the aftermarket with nearly 55,000 employees globally and 2017 revenues of $7.8 billion. Additionally, the company expects to separate its businesses to form two new, independent companies, an Aftermarket and Ride Performance company as well as a new Powertrain Technology company, in late 2019. Federal-Mogul Powertrain designs and manufacturers original equipment powertrain components and system protection products in the United States and internationally, its diversified production line consists of various products, ranging from powdered metal parts to space suits, including engine bearings, pistons, piston pins, piston rings, cylinder liners, valve seats and guides, spark plugs, ignition coils, transmission products, technical textiles and connecting rods. Federal-Mogul has received 16 Automotive News PACE Awards. The awards are for automotive suppliers that show innovation, technological advancement and business performance. Federal-Mogul received their first PACE Award in 2003; their most recent was awarded in 2016. 

Manufacturer of world-class pistons, piston rings, sintered parts and cylinder liners covering a wide range of applications including two/three-wheelers, cars, SUVs, tractors, light commercial vehicles, heavy commercial vehicles, stationary engines and high output locomotive diesel engines.



Widest range of piston rings and pistons varying from 30mm to 300mm diameter.

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The most modern production facilities at Bangalore, Patiala and Bhiwadi are certified TS 16949, ISO14001 and OHSAS 18001.

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Market leaders both in OEM and aftermarket. Exports to many countries.



Goetze and Goetze Brico provide leading-edge technologies and competitive solutions for original equipment manufacturers and the automotive aftermarket.

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Federal Mogul Slogan: A slogan is a short, memorable catch phrase, tagline or motto used to identify a product or company in advertisements. The advertising slogan, or business slogan most associated with Federal-Mogul, is:



Federal-Mogul

Mission

Statement

and/or

Vision

Statement

Mission Statements and Vision Statements are written for customers and employees of corporations. A Mission Statement can be defined as a sentence or short paragraph written by a company or business which reflects its core purpose, identity, values and principle business aims. The definition for a Vision Statement is a sentence or short paragraph providing a broad, inspirational image of the future. 

Federal-Mogul Mission Statement from the company's strategies: "Federal-Mogul Corporation drives global profitable growth through leading technology and innovation, quality excellence in products and services, speed to market, manufacturing expertise, lean principles, and strong environmental and safety standards."



Federal-Mogul Vision Statement from the company's strategies: "Federal-Mogul's worldwide leadership team is focused on leveraging the most advanced technologies and innovations in its neverending drive to achieve best-in-class results and exceed customer expectations.

History

Federal-Mogul has been creating value through innovation and leading technology for more than 100 years. Today, the company is a key player in the global marketplace, serving industries that range from automotive and commercial vehicles to railroad and aerospace. Customers know they can rely on Federal-Mogul's quality excellence in products, trusted brands and creative solutions.

This company started with a bold idea and over time grew into a FORTUNE 500 company with a global workforce thousands strong. The Federal-Mogul team has celebrated countless victories and worked hard to overcome the inevitable challenges. We invite you to explore our unique story through the links below. 1899 The Federal-Mogul Corporation was founded in 1899 by J. Howard Muzzy and Edward F. Lyon as the MuzzyLyon Company. The partners sold mill supplies and rubber goods, but they also set up an early subsidiary called the Mogul Metal Company. Under this new umbrella, they began to revolutionize the bearing industry. The pair started developing specialized metals to meet different bearing needs, and they were pioneers in diecasting replacement bearings to the right size and shape. Before the latter innovation, mechanics had to gouge out the old bearing from the motor block and pour in new metal. 1901 - The Mogul Metal Company created a new Babbitt metal called Mogul and sold it under the Duro and Mogul brand names. 1903 - The Muzzy-Lyon Company incorporated and elected its first board of directors. 1919 - The organization’s first stockholder meeting was held. 1921 - Total employment for the Muzzy-Lyon Company reached 500. 1924 - The company merged with Federal-Bearing and Bushing — a manufacturer of engine bearings and bushings — and became Federal-Mogul Corporation. 1929 -With a fellowship from the Battelle Memorial Institute, Federal-Mogul established a research division. The corporation’s sales reached $4.8 million. 1931 - Federal-Mogul introduced Equi-Poise boat propellers and formed a marine division. 1931 - Federal-Mogul introduced Equi-Poise boat propellers and formed a marine division. 1932 - The company developed a new alloy called C-100, which was the first new bearing material since the discovery of Babbitt metal. 1934 - Federal-Mogul’s research staff refined the C-100 alloy and released the new C-50 alloy. These developments revolutionized bearing manufacture and durability. Acquisitions in this time period included: Douglas-Dahlin Co., U.S. Bearings Co., Watkins Manufacturing Co., Pacific Metal Bearing Co., Superior Bearings Co. and Watkins Rebabbitting — Canada (first international acquisition). 1941 - Federal-Mogul became the world’s largest manufacturer of motorboat propellers. 1947 - The company opened a new research facility in Ann Arbor, Michigan, as total sales reached $85 million and employment hit 6,200. 1949 - Federal-Mogul celebrated its 50th anniversary. 1955 - The company merged with the Bower Roller Bearing Company — a producer of straight and tapered roller bearings — and became Federal-Mogul-Bower Bearings, Inc.

1956 - This newly formed entity debuted on the FORTUNE 500 list at number 350 as total sales reached $100 million. Acquisitions in this time period included: Hyde Windlass Co., National Formetal Co., Bearings Company of America, National Motor Bearing Co., National Seal Co. and Arrowhead Rubber Co. 1959 - The corporation installed an IBM computer at its Coldwater Service Headquarters in Coldwater, Michigan 1960 - Business operations were established in Switzerland. 1962 - Federal-Mogul-Bower opened its first overseas service center in Antwerp, Belgium. 1963 - The company’s Arrowhead Division facility expanded to produce components for the NASA Saturn launch vehicle. 1965 - The company merged with Sterling Aluminum Products and changed its name back to Federal-Mogul Corporation. 1966 - Federal-Mogul corporate headquarters were relocated from downtown Detroit to Southfield, Michigan. 1969 - The company’s sales reached $263.3 million. 1974 - Federal-Mogul celebrated its 75th anniversary as employment climbed to 13,500. Acquisitions in this time period included: Microtech Corp., Avondale Holdings, Inc., Rich Manufacturing Corp., National Grinding Wheel, Metal Removal Co., Carbide & Abrasives Tool Corp., Research Molding, Fox-Niedner Corp. and Taylor Industries, Inc. 1979 - NAPA® began selling Federal-Mogul parts under its brand. 1981 - The NASA space shuttle launched with Federal-Mogul’s Arrowhead® parts. Total company sales reached $833 million, while employment climbed to 15,000. Late 1990s - Federal-Mogul grew from a $2 billion supplier to a more than $6 billion supplier. Following this expansion, the company remains focused on a strategy of sustainable global profitable growth. 1999 - Federal-Mogul celebrated 100 years. 2001 - The company filed voluntary Chapter 11 and U.K. Administration petitions to separate its asbestos liabilities from its true operating potential. 2005 - Acquisitions in this time period included: Robert G. Evans Co., Hanauer Machine Works, Inc., Metaltec, Inc., Mather Co. and Fel-Pro, Inc. 2007 - Federal-Mogul Corporation emerges from Chapter 11. 2008 - Federal-Mogul Corporation lists Class A common stock on NASDAQ. 2012 - In September 2012, the company commenced operations as two independent business segments, each with a chief executive officer reporting to Federal-Mogul's Board of Directors, known as Federal-Mogul's Powertrain Segment and Federal-Mogul's Vehicle Components Solutions Segment. 2013 - Federal-Mogul purchased the Beru spark-plug business from BorgWarner, Inc.

2014 - In April, Federal-Mogul Corporation announced its intention to implement a holding company structure, changing the name of the company to Federal-Mogul Holdings Corporation. Following that announcement, in May Federal-Mogul announced that its Vehicle Components division would be renamed Federal-Mogul Motorparts. 2014 - The Federal-Mogul Motorparts Division acquired Honeywell and Affinia 2015 - The Federal-Mogul Powertrain division acquired TRW Engine Components business to solidify global leading supplier position 2017 - A subsidiary of Icahn Enterprises LP, formerly Federal-Mogul’s indirect 82% shareholder, acquires the remaining shares taking Federal-Mogul private. 2018 – Acquisition by Tenneco Clean Air, USA

MILESTONES 1954

Incorporated as a JV with Goetze Werke

1957

Ring & liner production

Patiala

1958

Piston production as escorts

Patiala

1960

Cast iron / Forged piston production Patiala started

1968

Pins / ring carrier production started

Patiala

1977

Piston / ring production started

Bengaluru

1982

Steel rings / Large bore locomotive piston Bengaluru

1985

Light alloy products

Patiala

1989

Auto thermic pistons production

Bengaluru

1990

Moly coated / IKA / chrome oil rings

Patiala

1992

Large bore rings / pistons for battle tanks

Bengaluru

1994

Composite pistons / new ring foundry

Bengaluru

1996

Escorts (Automotive Division) hived off into joint venture with M/S Mahle, Germany

1997

Goetze TP (India) Ltd. - Manufacturer of steel rings

2001

Merger of Federal-Mogul sintered products Ltd. with Goetze (India) Ltd.

2003

Merger of Escorts pistons activities with Goetze (India) Ltd.

2004

Introduction of chrome-ceramic rings

2004

Technical collaboration for pistons with Federal-Mogul Corporation

2006

Name changed "Goetze (India) Limited" to "Federal-Mogul Goetze (India) Limited"

2018

Acquisition by TENNECO clean air, USA Table 1.1

PRODUCTS:

1. PISTONS

Federal-Mogul Goetze India has state-of-the-art test bed facilities, design facilities for products and dies and tooling with CAD/PRO-E.

PROCUTION CAPACITY

: 13 Million Pistons per annum

PRODUCTION RANGE

: 30 mm to 300 mm Diameter

APPLICATIONS 

Bi-wheelers



Cars



SUVs



Tractors



Light Commercial Vehicles



Heavy Commercial Vehicles



Heavy Output Locomotive Diesel Engines

COATINGS 

Graphite



Tin



Phosphating



Anodizing



Moly Coating

FEATUERS 

Autothermic



Ring carrier / Alfin



Double C.I. grooves



Forged



Articulated

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Steel cap pistons



Pistons with cooling coil

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Thin-walled pistons for cars, Thin-groove piston.

PISTON RINGS

Goetze piston rings of OEMs and aftermarket in India has state-of-the-art design facilities for products, tooling with CAD/PRO-E/GLIDE SOFT and test bed facilities. Federal-Mogul Goetze India is dedicated to developing new technologies and continuously improving its products. Production capacity

: 55 Million Rings Per Annum

Product range

:

30 mm to 300 mm Diameter

GOETZE MANUFACTURES A WIDE RANGE OF PISTON RINGS FOR



Bi-wheelers



Tractors



Passenger cars & SUVs



Commercial vehicles (HCVs, MCVs & LCVs)



Locomotive engines



Stationary engines



Industrial

COATING ON RUNNING SURFACE 

Chrome ceramic plated rings (CKS)



Molybdenum coated rings

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Plasma filled rings

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Semi-inlaid rings

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Ferron filled rings

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Chrome plated rings

COATING 

Phosphating

Fig 1.1 Piston rings/cylinder liners CYLINDER LINERS

Federal-Mogul Goetze India manufactures wet and dry cylinder liners with honnong and sleeves for bi-wheeler applications for its quality conscious customers

APPLICATIONS 

Bi-wheelers



Cars



Tractors



Light commercial vehicles



Heavy commercial vehicles



Stationary engines

Production capacity

: 0.5 Million Per Annum

Product range

: 50 mm to 120 mm Internal Diameter

FEATURES 

Thin-walled



Plateau honed



With and without flanges

COATING 

Phosphating

Fig 1.2 Piston Pin / Cylinder

Chapter 2: About the department Piston Rings 1. Manufacturing Engineering Group (MEG) 1st day started off with loads of energy and enthusiasm, we were guided by Mr Srinivas Murthy. He spoke about the company, their global presence, their market and their products. Most of the products they manufacture are related to automotive industries, Federal-Mogul Powertrain manufactures pistons, piston pins, piston rings. MEG in particular takes care of the step by step manufacturing process of the products mentioned above. We were given a set of control plans of piston rings with design to go through. Control plan is nothing but a sequence of operations or processes that needs to be carried out to obtain a finished product. We were asked to keep the designs confidential since it was from a client who had a large base. Going through the designs and control process was the first task assigned to us. In the following days we were taken to the shop floor to enlighten us about the operations we studied in the control process. All the ring blanks coming from foundry were first rough grinded, medium grinded and heat treated all these were done in the Besley section

of the plant. The succeeding process like dual cam turning, CNC ADA, Gap sizing, inspecting, electroplating, stamping were all done in the Ring Machine Shop (RMS). Generally there are three rings in a piston, 

Compression ring



Scraper or Mid ring



Oil ring

Each ring has different functions, main functions of compression rings are to seal the combustion chamber from the crankcase and transfer heat from the piston to the cylinder. However, they also play an important part in controlling engine oil consumption. Function of scraper ring is to scrape lubricating oil away from the cylinder walls of a reciprocating engine. This prevents the oil from getting into the combustion chamber of the cylinder. This is also called as wiper ring. The last ring is the oil ring, this distribute and regulate oil within the cylinder wall and scrape it back into the crankcase. This is necessary to keep the cylinder wall lubricated with the cooler replacement oil, there by aiding the heat transfer and lowering the friction between the piston and the cylinder. Compression ring alone has sixty processes that are completed to attain a finished ring that can be shipped to the customers. Mid ring and oil ring have nearly more than fifty processes to get a completed product. 

Compression rings:

Keystone Ring: A compression ring with a wedge cross section. With its tapered sides, radial movement of the ring in engine operation will cause the axial clearance in the groove to increase and decrease. This greatly reduces ring sticking, as the ring continuously works its way free of the combustion residues. These rings are designed with an overall side angle of 6°, 15°, the larger angle being more effective against the tendency to coking. The keystone ring is used in the top groove in passenger car and truck diesel engines where ring sticking must be expected. Rectangular Ring: A piston ring with a rectangular cross section. This ring with its geometrically simple shape performs the necessary sealing functions under normal operating conditions. With a peripheral coating and appropriate barrel face the rectangular ring is today used mainly in the top groove in passenger car gasoline and diesel

engines. Besides service in internal combustion engines, rectangular rings are commonly used as rotary shaft seals, e.g. transmission seals.

Fig 2.1 Keystone ring



Fig 2.2 Rectangular ring

Scraper rings:

Napier Ring: This can be installed in the second groove in passenger car gasoline and passenger car and truck diesel engines, but has been almost entirely replaced by the taper faced Napier ring. It is now occasionally used only in the compressors of air brake systems. Taper Faced Napier Ring: Like on the taper faced ring, the periphery of this ring is designed with a taper in order to improve oil scraping and quicken running-in. These rings are used on the same applications as Napier rings.

Fig 2.3 Napier ring

Fig 2.4 Tapered face napier ring



Oil ring:

Coil Spring Loaded Double Bevelled Oil Control Ring: The wear coating gives the ring high long-time stability and makes it particularly suitable for operation mainly in diesel engines. The profile grinding of the lands allows close tolerances to be achieved on these critical working surfaces. Nitrided Profiled Steel Ring: A bevelled edge ring made from high-chromium profiled steel. Wear protection is provided by nitriding the ring all over. Like the chromed bevelled edge ring, this ring is chiefly used in diesel engines. Oil drainage is provided by means of punched holes.

Fig 2.5 Double Bevelled Oil Control Ring

Fig 2.6 Nitrided Profiled Steel Ring

2. Large Bore Ring Machine Shop We spent the last day of the week in large bore ring machine shop. Large bore rings are commonly used in loco engines and the prime and sole customer is the Indian Railways. The machines that were there in the ring machine shop sections were also present here. Here we were guided by Mr. Rathnakar Joshi. A single railway engine contains 18 pistons in it, which in turn contains 5 rings each. The diameter of rings varied from 228mm to 256mm. Two or more rings will be installed in a piston which together called as a set of rings. Further there were 5 types of sets. Sl no Name of the ring set

No of rings

1

3RV set

2+1

2

Chrome set

3+2

3

Plasma set

3+2

4

ELGI set

2

5

EMD set

Barrel+3+2

Finally were taken to inspection section. All the quality checks were done in a single room and there were five different kinds of inspection, 

Tangential/ Tension test



Face light/ closed gap test



Axial width test



Radial wall thickness



Visual inspection



Hardness test

After all these inspection the rings will be dispatched to Indian Railways. 3. Heat treatment: This machine shop also has furnaces for hardening and tempering, there are 4 furnaces and all the furnaces were busy running. The furnace was equipped with electric coils and lined by bricks. The piston rings coming from foundry will be installed in a mandrel and were loaded down into the furnace; each type of piston ring has different temperature to be maintained inside the furnace that shouldn’t be deviated from that specified temperature; all the rings will be kept for 120mins in it. 4. Besley section: Next we are taken to besley section and here we are guided by Mr. Ambarish. The blanks that are casted in the ring foundry make the input to this section. The main operations that are conducted here are splitting, rough and finished grinding. Grinding here is done in different stages. The machine used here is double disc grinding machine which grinds both the side of the blank at a time. 

Splitting is a process in which a single blank is split into 2 or more rings.



Rough and finished grinding are done depending on the requirement of the rings.



As the compression rings are conducted more operations and hence rough grinding is done.



Whereas scraper ring does not consists of as much operations as compression ring and hence required finished grinding.

Fig 2.9 Grinding Machine

5. Plating: Next we taken to electro plating section and we are guided by Mr. Keshav. Plating is a manufacturing process in which thin layer of metal coats a substrate. This can be achieved through electroplating, which requires an electric current, or through electro less plating, which is in autocatalytic chemical process. In either case, the technique results in one or several of the benefits which includes improved corrosion resistance, Decorative appeal, increased solderability, Enhanced strength, reduced friction, altered conductivity, Enhanced paint adhesion, increased magnetism. Three types of plating done here, 

Chrome plating.



CKS (chromium with aluminium oxide ceramic).



GDC (chromium with microdiamond).

First the input inspection is carried out for the rings from the machine shop in order to separate the scrap rings as plating is a costly process. 

Before plating the rings are pressed and fitted in mandrel to avoid axial plating.



This mandrel fitted rings are then cleaned using pre passivation in which cleaning of inner and outer diameter is done at 70 degree Celsius.



Then etching is carried out by supplying reverse current at 58-65 degree Celsius.



Then it is subjected to ultrasonic cleaner in which cleaning is done using transducer vibration.



Then subjected to plating.



For CKS and GDC plating primary or pre layer is chrome coated, then cracking is carried out by supplying reverse current and then CKS or GDC is coated, and final layer is again chrome coated.



Depending on the requirement sand blasting us done for surface roughness.



After plating the rings are demagnetised and final inspection is carried out.



After plating if there are any rings scrap dechroming is carried by dipping in HCL

Fig 2.10 Mandrel

Fig 2.11 Dipping tank

Fig 2.12 Dipping tanks 6. GTP line: Goetze Takehiko Piston ring (GTP) line manufactures piston rings for two wheeler motorcycles. Two types of rings are made based on plating, namely plain ring and chrome plated rings. Here we are guided by Mr. Manjunath. 7. Plane Ring Cell: This is a new building which comprises of machine shop in which plane rings are machined. The input to this is also from besley as blanks the following processes are carried out: 

Turning using double cam turning



Profile turning using ADA



Gap sizing



OD lapping



Phosphating



Laser stamping

8. FMTPR (Federal Mogul Takehiko Piston Ring): FMTPR is the new plant whose contributions are shared by USA, India and Japan. Here we are guided by Mr. Sukumar. This plant produces rings for two wheelers and four wheelers with machines imported from Japan. A new technology which converts coils into rings is adopted in this FMTPR. Rings ranging from diameter 47mm to 130mm. The coil used is mainly composed of steel. Nitriding process starts with three stage cleaning: 

Acid cleaning



Water bath



Ammonia gas



Cooling with nitrogen gas

Hardness of rings before nitriding process will be 300 to 450 HV, later jumps to 1100 to 1200 HV. Chrome coating is applied only on the periphery of the ring or on the lands. All the three rings are made from coils that are imported from Japan. 

Oil rings (3 piece ring):

The process is similar to that of top rings but with two rails and a spacer. All three components are made of coils that are thinner than top rings. Due to its flexible nature a spacer placed between them to support two rails. Coils are made to pass through machine known as spacer forming. Two gears press the coil to make impression on it. The design after forming resembles waves. A special type of coating known as ferrox coating is coated on rails to prevent rust formation and facilitate phosphating.

Piston A piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. In a pump, the function is reversed and force is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder.



Material: Pistons are made up for cast iron. Aluminium is added to increase piston efficiency. Silicon, Copper,

Nickel,

Magnesium

are

added.

A few other elements such as Titanium, Manganese, Chromium, Zinc, Lead, Tin, Vanadium, Zirconium, Sodium, Calcium and Phosphorus are added based on the requirement. 

Machined chips from machine shop pass through pre heating chamber. After cleaning and drying chips are put in to induction furnace for pre-heating. Pre melting is done in INSERTEC which has a capacity of 5 Ton.

Fig 2.12 Furnace

Fig 2.13 Holding furnace Quenching to get specified hardness There are two ways to quench the cast material: 1. Casting air quenching 2. Casting water quenching The piston is cooled down at a rate of 70oC/min.

A dimensional check is performed on the piston in order to ensure the right dimensions The dimension check include: Inner depth of piston, Bottom thickness, Wall thickness, Slipper distance, GP boss distance (GO and NO GO), oil drain hole size. In order to achieve the required hardness, the pistons are heat treated in a furnace of temperatures of about 215C to 230C. Hardness for S2N or FMB2 alloy is 110-150BHN Hardness for CSA12, CSA18 alloy is 90 to 120 BHN

Heat treatment cycle time is 5 to 9.5 hours

Fig 2.14 Heat treatment crucible

Inspection Hardness is checked as per sampling plan Visual inspection is carried out before moving to stores

Piston machining All process is carried out as per Standard Operating Procedure and control plan. Poke Yoke ensures pistons loading in one direction in slipper type pistons. 

Proof turning,



Facing,



Ring O.D plunge cut



Fixture seat boring,



Rough pin hole boring,



Grooving,



Crown facing and



Cavity machining



Finish pin hole boring etc. are few of the operations done on the piston.

Seat bore diameter is the key characteristic feature of a piston. Profile turning is done by a Cam-less profile turning machine. Critical characteristic feature is measured and process is carried out under statistical process control. Machines for Finish pin hole boring 

ZA-4 SPM



FB-43CNC



Takisawa TB-2000CNC



Weisser Frontor



Six Stations SPM

Cleaning After machining, the parts are loaded on cleaning machine. Coolant is sprayed on piston at 4kg/sqcm and hot air is blown over it.

Percentage of residual contamination permissible limits Mass of the remaining particles after spraying should be less than 10mg/1000cm2 on moistened component.

Isolating Defect components Some of the machines used for detecting defeat components are NDT testing Ultrasonic and Eddy current for LVD pistons.

Ultrasonic inspection is a non-destructive method by which high frequency sound waves are introduced into the object being inspected.

Fig 2.15 Ultrasonic inspection Most ultrasonic inspection is done at frequency between 0.5 and 20 MHz. The sound waves travel through the material with some loss of energy (attenuation) due to material characteristics Piston surface treatment: A surface treatment is a process applied to the surface of a material to make it better in some way, for example by making it more resistant to corrosion and wear. A surface treatment is a process applied to the surface of a material to make it better in some way, for example by making it more resistant to corrosion or wear. Stages involved in Phosphating: 1. Degreasing is a simple process that use solvents to clean the unwanted fatty acids like oil, coolant etc. Solvent: Gardo clean 5375 Temperature: 65o – 70 oC 2. Water rinse – 1 – Continuous water flow 3. Water rinse – 2 – Continuous water flow 4. Demineralised water – Hydrochloric acid Temperature: 80 ± 5 oC 5. Phosphating bath – Solvent: GB 40584 GB 7134 Temperature: 75± 5 oC 6. Water rinse – Continuous flow

Tin Coating: Tin coating is another kind of surface treatment used to improve anti frictional properties of a product. Federal Mogul delivers this type tin coated piston to KUBOTA. All the processes are similar to Phosphating with one change. Etching is an additional carried out in an etching tank, process done on the machined piston done if demanded by customer.

Fig 2.16 Surface treatment bath Screen printing is done for initial lubrication purpose:

Fig 2.17 Screen printing machine Casting of Piston from Aluminium Keywords Piston; Metallic mould; Piston core; Crucible furnace; Fettling.

Piston Core Production Pure silica sand was used. The sand was washed with sufficient water for several times, drained in a sack and dried under sun. This was to reduce the clay and salinity contents in the sand. The dried sand was sieved to remove coarse sand grains. This was to reduce metal penetration during casting and to remove other foreign bodies in the sand. A specific quantity of the sand was fetched and starch was added to the sand and mixed thoroughly with the sand for two minutes. The starch addition was to improve collapsibility and ease of knockout. Sodium silicate (aqueous) binder was added and the mixture mixed for three minutes. A total mixing time of five minutes was used. The forming of piston core was done using split core box in figure 1. The core box cavity was rammed full of mixed core sand to form the piston core. After ramming, the core box was gassed with gas contained in cylinder and the core stripped out afterwards. A typical sand mix is shown in Table 1.

Table 1. Sand Mix Composition of Core [4] Materials

% Composition by weight of core

Weight in 153g

Silica sand

96.5%

147.65

Starch

1.5%

2.3

Sodium silicate

2%

3.06

Carbon (iv) oxide (C02)

0.5%

0.76

Melting Furnace The furnace used for the melting of the aluminium scrap was crucible furnace, which makes use of coke for burning. The process involved re-melting clean scrap; therefore principal concern was to avoid melting losses and gas inclusion. Fast melting with minimum disturbance was aimed. The melting of scrap with crucible is shown in figure 1.

Piston Production The piston production was carried out using metallic mould machine shown in figure 1. At the foundry the mould cavity was prepared via coating and preheating. The coating was done using plumb ago dust with isopropyl alcohol as the carrier uniformly applied using spray gun. The mould cavity was preheated to 200°C using oxy-acetylene flame. The preparations allowed the mould to readily accept the molten metal when poured and also help minimize the number of unacceptable casting that may be obtain during the establishment of operating temperature. After mould cavity was prepared and core placed in properly, molten metal was scooped out with a ladle from the crucible and poured into the mould through the sprue. Charging and melting was for 1.5 hours. The piston scraps were heated 10°C above the specified pouring temperatures. This was to compensate for temperature loss during pouring of the melt. The pouring temperature was measured by a thermocouple. In the pouring ladle, the tip of the instrument was allowed to make contact with the base of the molten metal contained in it. Two temperature readings was noted and recorded accordingly. The first was the temperature reading at the beginning of pouring of the melt into the mould and the second was temperature recorded immediately the mould was filled up. The average of these two temperatures calculated was the temperature for the pouring. In other to achieve minimum composition loss; excessive stirring, overheating of the molten metal and prolonged heating were avoided. In minimizing impurity use of dried charge material, ladles tools heated by evolving furnace heat, cleaned and de-carbonized piston scraps were emphasized. Dissolved hydrogen reduction and oxide separation was carried out by plunging tablets of hexachloroethane into the melt at 10°C above pouring temperature of 700°C. The hexachloroethane tablet added was 15.3g against charged weight of 6.12kg. The furnace environment was heated by charcoal fire around the furnace environment to drive off moisture, thereby preventing moisture dissociation near the molten metal surface. The poured molten metal was allowed to solidify in the mould before it was removed and placed into a bin of hot water. The water was used to reduce the cooling rate and hence facilitate a more even settling of

the hot cast metal. The cooled casting was removed from bin of hot water and fettling operation was conducted using the normal methods. The cast pistons were fettled, placed on a lathe and machined to standard specification of AX 100 piston. The piston after machining was subjected to surface finish and dimensional accuracy by touch, visual inspection, and vernier calliper.

Inspection of Piston after Test After eight exhausting hours using cast piston, the engine was disassembled, inspected in the areas of piston ring deposit accumulation, piston ring sticking and measured for wear. The test process was also repeated using new imported piston. The rating used was based on a scale from 1 to 10. The higher the rating, the better the evaluation or performance of the piston in the specific area rated. The piston grooves was rated as to the state of wears and the degree of circumference around the piston that they were worn. Deposits are evaluated by appearance, ranging from 10 (clean- absence of deposits) to 0.0 (maximum deposits).

Spectrographic Test on Imported and Cast Piston The chemical compositions were carried out using mass spectrometer to determine the exact alloy composition on imported piston and cast piston-specially since Mg easily volatilizes. The samples were first ground with 120 μm SiC paper and then analyzed. Five recordings were made on each sample and the values averaged.

Results and Discussion

The chemical composition comparison of the piston alloys is presented in Table 2. The chemical composition analysis was done in other to achieve an extended comparison, with a view of ascertaining if there was a substantial variation. It subsequently determines whether measures adopted to prevent inclusions and composition loss during casting achieved result.

Table 2. The Chemical Composition of the Piston Alloys Elements

Imported Piston

Cast Piston

Variation

[%]

[%]

[%]

Si

22.86

22.29

-2.5

Fe

0.413

0.427

+3.3

Cu

0.80

0.774

-3.2

Mg

0.60

0.57

-3.3

Ni

0.81

0.794

-2.0

Ti

0.086

0.083

-3.2

Li

0.117

0.113

-3.7

Al

Bal

Bal

Bal

The effect of heat-treatment on aluminum-based piston alloys

In this study effect of heat-treatment on the mechanical properties of aluminum-based piston alloys has been investigated. AlCu4MgNi alloys and AlSiCuMgNi alloys with 10%, 12%, 18% and 24% Si were utilized for this purpose. After melting, alloys have been cast in the metal mold at 800 degrees C and solidified. The solution treatment has been performed at 500 degrees C for 5 h and then quenched. The samples have been aged at 180 degrees C for 9 h to observe the effect of aging on hardness properties. (c) 2006 Elsevier Ltd. All rights

reserved.

This task is performed in order to get awareness of all the process involved machine used for different process and the product process characteristics involved in the production of the piston .the product and process characteristics is provided by customer to meet their specification,based upon these characteristics ,the operator will write CNC code and set in to the CNC machine. Before starting the operation according to required dimension, the operator will prepare the setting piston and it sent to the metallurgy dept after getting approved from the metallurgy dept ,the setting piston is considered as the reference piston the measurement of the entire machine piston is made std if approved by authorities .if there is any small variation in the dimension of the setting piston ,the entire lot of piston will be rejected and it is considered as scrap ,so as the operator has to frequently check the dimension of the piston by using piston to avoid scrap.

Chapter 3: Tasks Performed

INTERNATIONAL ORGANISATION FOR STANDARDS (ISO)

The International Organization for Standardization (ISO) is an international standard setting body composed of representatives from various national standards organizations. Founded on 23 February 1947, the organization promotes worldwide proprietary, industrial and commercial standards. It is headquartered in GENEVA, SWITZERLAND, and works in 164 Countries.

NAME AND ABBREVIATIONS

The name of the organization in French is Organisation Internationale de normalisation, and in Russian, Mezhdunarodnaya organizatsiya po standartizatsii. ISO is not an acronym. The organization adopted ISO as its abbreviated name in reference to the Greek word isos (meaning "Equal"), as its name in the three official languages would have different acronyms. Whatever the country, whatever the language, the short form of our name is always ISO." Both the name ISO and the ISO logo are registered trademarks, and their use is restricted.

HISTORY OF ISO

The organization today known as ISO began in 1926 as the International Federation of the National Standardizing Associations (ISA). It was suspended in 1942 during World War II, but after the war ISA was approached by the recently formed United Nations Standards Coordinating Committee (UNSCC) with a proposal to form a new global standards body. In October 1946, ISA and UNSCC delegates from 25 countries met in London and agreed to join forces to create the new International Organization for Standardization; the new organization officially began operations in February 1947.

INTERNATIONAL AUTOMOTIVE TASK FORCE (IATF)

IATF 16949:2016 (1st edition) represents an innovative document, given the strong orientation to the customer, with inclusion of a number of consolidated previous customer specific requirements.

ISO/TS 16949 (1st edition) was originally created in 1999 by the International Automotive Task Force (IATF) with the aim of harmonizing the different assessment and certification systems worldwide in the supply chain for the automotive sector. Other revisions were created (2nd edition in 2002, and 3rd edition in 2009) as necessary for either automotive sector enhancements or ISO 9001 revisions. ISO/TS 16949 introduced a common set of techniques and methods for common product and process development for automotive manufacturing worldwide.

In preparation for migrating from ISO/TS 16949:2009 (3rd edition) to this Automotive QMS Standard, IATF 16949, feedback was solicited from certification bodies, auditors, suppliers, and OEMs to create IATF 16949:2016 (1st edition), which cancels and replaces ISO/TS 16949:2009 (3rd edition).

The IATF maintains strong cooperation with ISO by continuing liaison committee status ensuring continued alignment with ISO 9001.

OVERALL EQUIPMENT EFFECTIVENESS (OEE) OEE is an abbreviation for the manufacturing metric Overall Equipment Effectiveness. OEE takes into account the various sub components of the manufacturing process – Availability, Performance and Quality.

After the various factors are taken into account the result is expressed as a percentage. This percentage can be viewed as a snapshot of the current production efficiency for a machine, line or cell. OEE = Availability x Performance x Quality

TOTAL EQUIPMENT EFFECTIVE PERFORMANCE (TEEP) TEEP stands for Total Effective Equipment Productivity (Performance). TEEP is a performance metric that shows the total performance of equipment based on the amount of time the equipment was present. Typically the equipment is onsite and thus TEEP is metric that shows how well equipment is utilized. TEEP = Valuable Time / Total Time

OVERALL ASSET EFFICIENCY (OAE) Overall Asset Efficiency (Asset Turnover) is a financial ratio that measures the efficiency of a company's use of its assets in generating sales revenue or sales income to the company. Companies with low profit margins tend to have high asset turnover, while those with high profit margins have low asset turnover. Companies in the retail industry tend to have a very high turnover ratio due mainly to cutthroat and competitive pricing. OAE = Valuable Time / Scheduled Time

Observations done in Piston Machine shop line: Federal Mogul Takehiko Piston line manufactures piston for two wheeler motorcycles. Two types of pistons are made based on plating, namely tin coated pistons and chrome plated pistons. The processes carried out can be split into eleven broad categories that are given below in the table. These pistons are specifically used by two wheeler motor segments with clearance volume ranging from 100cc to 200cc. We were made to observe each process very carefully, here pistons are casted. The Oval coiling machine drags the formed wires and converts them to coil like structures that look oval in shape and in the same machine coils are converted into rings by splitting. Stress relieving machine reduces the residual stress that is developed in the rings; residual

stress occurs when a material is stressed beyond its elastic limit and remains after the loads are removed. Axial grinding is done as per the control plan given to the operators by the MEG department, grinding is done to reduce the width of the rings to match it the actual design with tolerance as per client specific design. The next process is known as lapping done in lapping machine, this line is known as A1 line. Gap sizing machine grinds the edges of split area in the rings. This ensures the gap between two edges to remain uniformly. Nitriding is the next operation performed on the rings and take place in three stages, 

Acid cleaning



Water bath



Phosphate bath



Nitriding with ammonia at 480 0C for 4 hours



Cooling with N2 gas for 1 hour

Phosphating is done to increase the life of pistons by reducing corrosion, done in a phosphate bath. Inner diameter is lapped with Lapping machine, here the inner surface rubbed against an abrasive to give finish on the inner circumference and to chamfer also. One or more parts are machined at the same time in a batch process. The abrasive is usually mixed with a liquid vehicle, either oil or water based. The pieces being lapped are captured in retaining rings. Work holders also called "carriers" may be used to keep the parts separated to prevent damage to their edges. The parts are dragged across the lap plate surface on to which the abrasive is being fed. Finally the rings are sent to quality check and inspection, to packaging to the customer.

Oval coiling machine

Nitriding

Phosphating

Stress relieving machine

Gap cutting machine

OD Lapping machine

Inspection

Fig 3.1 Flowchart of pistons

Axial Grinding machine

Packing

Physical Vapour Deposition: This technique is specifically used to coat the piston rings with chromium, hence the name chrome rings. The PVD equipment will be about 4 ft in height and 4 ft in diameter. The material to be deposited (e.g. titanium, chromium) will be at the top, as shown in schematic Fig 3.1

Figure 3.2: Schematic of a PVD chamber

The chromium will be in the form of a disc of 1 inch thickness and 5 or 6 inches diameter. At the bottom, piston will be kept. Apart from these, there will be facilities to allow gases into the chamber and to evacuate the chamber with vacuum pump and electrical connections to apply very high voltage (of the order of 10000 V). The negative plate will be near the tungsten and the positive plate will be near the wafer. Chromium (or any other material in its place) is called target. When the ions hit the target, a few atoms will break away from the target and fall on the wafer. This is a very simplified description of PVD process. PVD is also called sputtering. First the air in the chamber must be removed and vacuum must be created this is done by rotary pump. Then argon gas sent inside and a low pressure will be maintained. If high voltage is applied to the plates, a plasma will be generated. The plasma will have electrons and positive argon ions. The plasma cannot be generated by normal 230 volts. The positive argon ions will be attracted towards the negative plate. They will move towards

the negative plates and hit the chromium with high force. That is why chromium is called target in this process. This process usually takes 8 hours, and heated at around 700 0C. This process is usually carried out on 21 axis and 18 axis mandrel, this depends on the size of the piston rings. Piston rings are loaded automatically when the chamber inside reach 450 0C. Anode gas is pumped into the chamber, this whole setup is enclosed and temperature maintained at 21 0C. Cathode: Brass

Loading

Pumping

Anode: Substrate

Heating

Bombardment

Coating

Cooling

Fig 3.3 Flowchart of Physical Vapour Deposition

Vent

Substrate unloading

Observations done in GTP line: Goetze Takehiko Pistons (GTP) line manufactures piston for two wheeler motorcycles. Two types of pistons are made based on plating, namely plain tin coated and chrome plated. Pistons are die casted in piston foundry, pistons are sent to besley section where the pistons are rough grinded and medium grinded with grinding machines. These pistons come to GTP line piston machine shop. First process is known as double cam turning done on CNC double cam turning machine, simultaneously the rings are cut to create gap which is known as gap cutting. ADA machine finish turns the rings on the mandrel, rings are loaded by core loading machine and then finish turned. Gap sizing is done similar to FMTPR process. Chromium bath or ceramic bath or diamond coating is done based on the requirement of the customer. Deburring clears all the rough grains on the inner diameter and keeps it smooth. Axial grinding or finish grinding is done by axial grinding machine. Degreasing bath cleans the piston rings from dirt and other unwanted matter. Honing machine finish the outer diameter and is a finishing operation. Phosphate bath ensures that no corrosion take place while the rings are at service. The rings are inspected visually and with instrument, finally send it to packaging section where the rings are delivered to the customer after loading the pistons into a box.

Pistons of four wheeler

Pistons of excavator

MACHINING PROCESS OF PISTON

SL.

PROCESS

NO

NAME

1)

Rough OD

MACHINE NAME

PMT/M8R

PRODUCT CHARACTERISTICS

PROCESS CHARACTERISTICS

OD=90.8(+-1)mm

Speed 800 rpm

turning and

Width:12mm

Feed 4 mm/rev

crown step

Height :10.9mm

Feed 0.9 mm/rev

facing

Top OD 93.3+.2mm Middle OD 93.3+-0.2mm Bottom OD 93.3+-0.2mm

PMT Machine

2)

Seat boring

KD2 finish

Height 82.9+-0.1mm

Speed 1150rpm

and finish

Total height from fixture

Cam feed 0.05 mm/rev

fixture

75.9+-0.1mm

Feed 0.22rmm/rev

Fixture dia 84.3335mm Centre dia 3.15mm

Seat Boring and Finish Fixture Machine

Rough Pinhole Boring and Oil Hole Drilling Machine

SL. NO

3)

PROCESS NAME

Rough

MACHINE NAME

WB11

PRODUCT CHARACTERISTICS

PROCESS CHARACTERISTICS

Rough pinhole dia

Speed 1100rpm

pinhole

+0.1mm.

Feed cam feed

boring

pinhole bore height +0.1mm,14.4mm thickness4 +- 0.4mm

4)

Oil hole

WB11

drilling

Oil hole dia - 2.8mm

Speed 600rpm

no of holes - 4

Speed manual

Pitch Hole - 60degree

5)

OD turning

M8 finish

2nd groove dia 81.7+-0.2mm

and finish

3RD groove dia 0.3+-0.2mm

AL grooving

2nd width 0.08-0.06mm 3RD width 0.04-0.02mm

Speed 600 rpm

Turning and Finish AL Grooving Machine

Finish OD 6)

FD1/FD2

DI 11.5mm,

Speed 651 rpm

profile

D360mm,

Feed 0.28 mm/rev

turning.

D462.8mm105+-70.3mm D681mm

Finish OD Profile Turning Machine

7)

8)

Separating

LB17

Separating depth 0.1mm

Speed 500 rpm

machining

LB20

Separating depth 0.6mm

Feed manual

Finish pinhole

ZA4

Pinhole dia30.01

Speed

boring

+-0.0035mm Compressing height 45.5 +- 0.05mm

2500rpm to 2800rpm

Chapter 4: Outcomes The internship training program was very beneficial informative and thoroughly enjoyable experience it was a wonderful platform to gain insight from close quarters of innumerable technical and theoretical concepts imparted in the course of B.E mechanical engineering. We specifically learnt how an industry works, being an intern at any OEMs will help us to understand how international standards are maintained inside outside the premises of the company. Industrial safety was given utmost importance there we more caution boards than any other machines inside. Nobody will be allowed inside if one isn’t wearing safety shoes and glasses provided by the company. Ear plugs is made mandatory while working in foundry shop, most of the sound and noise is generated in foundry shop. So in general PPE’s play important role in protecting us from hazards and accidents. Lot of stress is made on safety of individual and the factory. Being an automobile industry Federal Mogul looked at the environment as mother of all its tasks, they are keen enough to deliver the happiness being around nature to its work force. Huge trees inside not only reduce carbon emission but also inspire the workers to perform tasks more soothingly and pleasantly. So this reminds me to devote my time for conserving and protecting nature and it’s resource in hand also work for the sustained developments set by the company. And also the management skills of managers and their assistants looking after a shop floor helps us to take care of each worker and pay attention to their problems and solve them patiently.

Personal protective Equipment

Production:  I have observed the process piston manufacturing method and different types of machine and their function.  Understanding the particular tool for machining process.  Understanding the visual management (5-s) maintaining shop floor.  The 5-s management describes the following : Sort: sort out and separate that which is needed and not needed in the area. Straighten: arrange items that are needed so that they are ready &easy to use .clearly identify location for all items so that anyone can find them &return them once the task is completed. Shine: clean the workplace &equipment on the regular bases in order to maintain std &identify defects. Standardize: revisit the first three of the 5s on a frequently base and conform the condition of the real place using std product. Sustain: keep to the rules to maintain the standards &continue to improve every day.

5’s of industry

This training program has provided me an opportunity to understand various steps and sections involved in the industry. I feel honoured to interact with some of the best technical personnel in well reputed industry like FEDERAL MOGUL. I would like to express our gratitude to all the staff of FEDERAL MOGUL for helping me in every aspect.