Menon Pistons Limited, Plant II, MIDC Kupwad

Report of In-Plant Training

IN

Menon Pistons Limited, Plant II , Kupwad

By 1. wale!ar "ai#$a% P. '.Bagwan (u$el . +.Kulal (an,ay -. &.Ta!ale B$anudas B. ).*erwade Pramod B. ..Pat!i (aura#$ .

Submitted in partial fulfillment for confirring -egree of Ba/$elor of Te/$nology 0Me/$ani/al1 2f ($i%a,i 3ni%ersity Kol$apur

-epartment of Me/$ani/al 4ngineering T(5s (an,ay B$o!are 6roup of Institutes, Mira,. '711-'71'

Menon Pistons Limited, Plant II, MIDC Kupwad

1. COMP !"
Location

P#O$IL%

Menon Pistons Limited, Plant II &'1, MIDC, Kupwad (loc), Sangli * +1, +1,, Ma-aras-tra, India.

Mission . Core /alues0'

/ISIO! 1o be t-e world2s leading pro3ider of auto component manufacturing . total engineering solutions to automobile manufacturers across t-e world. MISSIO! 1o pro3ide inno3ati3e products of world class 4ualit5 at reasonable prices.

6ualit5 Polic50
primar5 responsibilit5 at Menon Pistons Limited is to offer cost effecti3e 4ualit5 products to its customers7

1owards 1-is 8e Commit Oursel3es0

1o meet t-e Customer e9pectations of current : future needs. 1o co'ordinate and ac-ie3e impro3ements and effecti3eness in areas of 4ualit5 and processes on a continual basis. 1o endea3or to upgrade tec-nologies and s5stems and practices to meet statutor5 and regulator5 re4uirements. 1o ac-ie3e -ig-er goals of e9cellence b5 establis-ing ob;ecti3es and targets at rele3ant and appropriate inter3als and monitor t-eir effecti3eness periodicall5.

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Menon Pistons Limited, Plant II, MIDC Kupwad

wards . Laurels0'
1-e $irst Compan5 in India to de3elop #ing Carrier Pistons (%S1 /endor ward from Maruti =d5og Ltd in t-e 1>>+'>? @S-ip * to * =se7 Status b5 C=MMI!S I!DI L1D since 1>>? $aster De3elopment ward from Kirlos)ar Oil %ngines Ltd ISO:1S0 1,>+> Certified b5 1=/ Suddeutsc-land in <AA? O=1S1 !DI!B S=PPLI%# $O# %CC%LL%!1 P%#$O#M !C% award from C=MMI!S Broup in Dul5 <AA,

Resear/$ and -e%elopment8Man5 applications re4uire -ig- -ardness at surface . also core strengt. toug-ness to wit-stand impact stress. 1o ac-ie3e t-is propert5, process used to includes carburiEing, c5aniding, nitrating, and carbonitriding. In carburiEing process, carbon is diffused into part2s surface to a controlled dept- b5 -eating part in carbonaceous media. 8it- t-is arrangement, MPL will -a3e access to t-e latest in Piston 1ec-nolog5, -igstrengtmaterials, e4uipment and mac-iner5 for Design:De3elopment and manufacture of Pistons to cater to t-e needs of manufacturers to satisf5 t-eir re4uirements of Piston designs wit- and wit-out @Cooled Baller57 to compl5 wit- t-e emission legislations pre3alent and t-ose in t-e offing in future. 1o satisf5 t-e demands of t-e %ngine manufacturers for low pollution and -ig- efficienc5, MPL -a3e been putting a lot of efforts to produce Pistons wit- lig-t weig-t, -ig- intensit5 and low friction b5 performing c-ec)s for structural design of Pistons, anal5sis of internal stress, mec-anical and 1-ermal Load and 3erification of Pistons of designs b5 1-ree dimensional $inite element met-od in co'operation wit- t-eir partner M:s. Dong "ang Piston Co. Ltd.

Menon Pistons Limited, Plant II, MIDC Kupwad Design and manufacturing acti3ities are continuall5 impro3ed b5 -a3ing in '-ouse testing facilit5 for t-e 3alidation of t-e product before offering t-e product to t-e Customer. MPL -a3e been acti3el5 associated wit- t-eir Customers in carr5ing out trials using t-eir test facilit5 for arri3ing at mutuall5 acceptable performance le3els. 1-e e9perienced Design team of 5oung %ngineers at MPL pro3ides two dimensional and t-ree dimensional solid modeling facilities and anal5sis utiliEing t-e Pro'% 8ildfire*< foundation pac)age for t-e Surface modules, ad3ance Modeling e9tension and t-e rele3ant C D and C % facilities. 8it- t-e e9perienced team, MPL wor)s as a complete solution pro3ider to its Customers b5 underta)ing t-e product de3elopment from conceptual stage to product realiEation wit- t-e s-ortest possible lead time. MPL stri3es -ard to pursue Customer satisfaction t-roug- t-eir Process Control and non destructi3e 6ualit5 c-ec)s as well as maintenance and impro3ement of t-e 6ualit5 S5stems. (5 use of rigorous 6ualit5 Standards and S5stems at 3arious stages of manufacturing wit- t-e computeriEed On'Line *Statistical Process Control. 1ec-ni4ues, MPL ensures t-at products w-ic- reac- t-e customers are defect free and -a3e been produced witt-e -ig-est International 6ualitati3e Standards. MPL -as been awarded and Certified b5 t-eir 3alued Customers for t-eir 6ualit5 related acti3ities and -a3e been recogniEed as t-e most @6ualit5 Conscious and Consistent7 Supplier. are practiced in all locations. ll Plants of MPL -a3e been certified for @ISO:1S 1,>+>7 <AA< and t-e s5stems and procedures based on 1PM, Si9 Sigma principles

Menon Pistons Limited, Plant II, MIDC Kupwad

Produ/t Range8In 1>G?, MPL set up its Second Plant in Sangli w-ic- is around ,A Kilometers from Kol-apur and manufactures around <AA,AAA Pistons annuall5 primaril5 for catering to t-e Diesel %ngines for Industrial purposes, irrigation: gricultural and Small Diesel Benerator Sets. part from t-e manufacture of Pistons, t-is Plant is full5 e4uipped to manufacture Budgeon Pins in t-e diameter range of 1, mm to GA mm wit- well supported Laborator5 and sop-isticated manufacturing and measuring e4uipment to -eat treat:Mac-ine:Brind:Super finis- Budgeon Pins guaranteeing t-e Beometrical accuracies and mec-anical strengt-:-ardness for long and trouble free operation on t-e %ngine. MPLHs Product #ange boasts of Piston ssemblies for di3erse arra5 of -ig- 1ec- features catering to t-e wide 3ariet5 of applications suc- as *

1. &ea35 Dut5 Diesel %ngines for Power Beneration:Off &ig-wa5 /e-icles:Bas %ngines

$ig.1 M8 Piston

fig. rticulated Piston

$or &ea35 Dut5 Diesel %ngines for Power Beneration:Off &ig-wa5 /e-icle applications, MPL de3elop and produce Pistons wit- diameters ranging from 1FA mm to 1>A mm featuring Single lfin and Dual lfin Bra3it5 Die Cast Pistons. MPL manufacture t-ese Pistons on a dedicated manufacturing facilit5 witspecial purpose C!C Mac-ines to produce comple9 OD Profiles, and Pin bores wit- O3al (ore, trumpet bore or reliefHs as per t-e re4uirement. 1-e complicated Core Profiles featuring on t-ese Pistons are generated appl5ing FD modeling facilities using Pro'% 8ildfire'< foundation pac)age for surface modeling, ad3anced modeling e9tension and 1ool Design Pac)age for ?

Menon Pistons Limited, Plant II, MIDC Kupwad manufacturing to ac-ie3e targeted sections and effecti3e control on t-e weig-t of t-e Piston for optimum balance of reciprocating masses. Some of t-e special features w-ic- are pro3ided in t-e design of t-ese bigger siEe Pistons IDiameters of 11A mm to 1JA mm rangeK 1wo pieces constructions of Pistons I #1IC=L 1%D PIS1O!SK witforged C-rome Mol5 Steel Crown coupled witluminium llo5 S)irt -eld toget-er b5 a Piston Pin w-ere t-e guidance and sealing function are separated from one anot-er. (ecause of t-is design, t-e s)irts is better s-ielded from -ot Piston crown and ring Lone and can, t-erefore, be installed wit- smaller clearances t-an t-e one'piece Piston, w-ic- -as a positi3e effect on 6uiet running.

'. *ea%y9Medium9Lig$t :ommer/ial "e$i/les wit$ -iesel 4ngines.

$ig. Cooled Baller5 Cut Section

fig. 1 1 +SP %uro III Piston

In 3iew of t-e ensuing legislations and t-e )eenness of t-e Bo3ernment to pro3ide en3ironmentall5 friendl5 ambience, t-e modern Internal Combustion %ngines need to introduce !ew 1ec-nologies for compl5ing wit- t-e emission legislations.

Menon Pistons Limited, Plant II, MIDC Kupwad

1-e new 1ec-nologies call for design of Pistons to wit-stand increased specific power output, increased in;ection pressures, -ig- pressure turbo c-arging wit- after coolers, to compl5 wit- stringent emission regulations w-ile satisf5ing t-e re4uirements of low fuel and lube oil consumption. MPL manufactures wide range of Pistons in diameter range of J? mm to 1FA mm wit- and wit-out @Cooled Baller57 features. 1-e design and manufacturing facilities a3ailable wit- MPL enables t-em to design, produce and optimiEe t-e features suc- as, @ as cast Oil drain Poc)ets7, utot-ermic: utot-ermatic Piston wit- @control e9pansion7, Steel struts to pro3ide lesser fitting clearances for reduced noise le3els, Budgeon Pin (ore offset for effecti3e load balancing:noise control, . Cooled Baller5 Pistons

+. Bi-w$eeler 0& (tro!e1 9 (mall 4ngine ppli/ations

$ig. 1/S /ictor:(o9er: &ero &onda

$ig. Copeland Pistons

wide range of Pistons for < Stro)e and + Stro)e %ngines in t-e diameter range of +A to ,A mm for powering t-e Scooters, Motor C5cles and #efrigeration ir Compressors are made from %utectic and &5pereutectic w-ic- are 3er5 cost effecti3e and pro3ide 3alue for t-e mone5. luminium llo5

Menon Pistons Limited, Plant II, MIDC Kupwad 1-ese Pistons are offered in attracti3el5 pac)ed containers as assemblies consisting of Pistons, Budgeon Pin. MPL produces about 1.F million pistons annuall5 of +1mm diameter for #efrigeration ir compressor sealed units. 1-ese are manufactured on special purpose mac-ines wit- close tolerance and e9tremel5 good surface finis- to pro3ide H6uiteH running of t-e compressors.

&. 6udgeon pins

$ig. Budgeon pins 1-e5 mainl5 manufactured pistons, Pistons rings . gudgeon pins. 1-e5 are /ander for 1F companies from w-ic- ma;or are automobile companies. 1-e5 suppl5 pistons for 1elco, (a;a;, Ma-indra . Ma-indra, . Kirlos)ar oil %ngines . Coment Diesel %ngines, Cummins India Ltd.

8or)ing S-ifts
1-ere are F s-ifts per da5. In all t-ree s-ifts production is done continuousl5. 1urno3er of compan5 is about 1< to 1? corers per 5ear. Compan5 is -a3ing ISO0 >AA . 1S'1,>+> certificate called 1=/.

;23N-R< PR :TI:4(
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Menon Pistons Limited, Plant II, MIDC Kupwad

:$arge Material 1-e raw material re4uired for pistons casting consist of ingots, re;ected pistons . cut off pro;ections, etc. luminum

:$emi/al :omposition s per t-e c-emical results in c-emical composition are depends on t-e re4uired properties of piston li)e -ardness. $or e9ample c-emical composition of l-B3TT2N ( MPL4 LM-1+91=) is gi%en #elow8 l * G+.,JM Cu * A.,?M !i * A.>?M Pb * A.A1M Si * 11.J?M Mn * A.1?M Ln * A.1FM Sn * A.AA<M $e * A.+,M Mg * 1.<M 1i * A.A1M

ppro%al of Material fter receipt of material, material s-ould be c-ec)ed for its c-emical composition i.e. material appro3ed in t-e lab b5 testing. &ere we can see t-at material recei3ed from Soppier is re;ected.

llo5 melting '

1-e c-arge material is melted in melting furnace w-ic- is oil fired, open -eart- furnace. In t-is furnace t-e furnace oil . air at -ig-er temperature w-ic- causes for combustion. 1-e temperature arc-i3al is J+A to J,A degree C . time re4uired is -alf -our. 1-e capacit5 of furnace is <AA'FAA Kegs.

lloy $olding -

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Menon Pistons Limited, Plant II, MIDC Kupwad In t-is process molten metal is broug-t . collected into -olding furnace. 1-is operation is done to -old t-e molten metal . maintain re4uired temp to )eep in melting condition. fter collecting molten metal in -olding furnace t-e CL%!OL powder is spread o3er it for remo3al of slug Ii.e. drossK, etc. from melt.

6as > :$emistry :$e/!ing In molten metal mi9 alrefine , powder in it . stir it well. 1-en wait for 1? to <A min. at J<A to J,A NC or mi9 modified al refine , powder in it . stir it for < to F min at J+A to J,A NC. 1o remo3e internal -5drogen gases mi9 aldegas AJ tablets in molten metal at ,GA to J<A NC . stir it. In gas test, c-ec) w-et-er gas is remo3ed during solidification . in c-emistr5 test, c-ec) for all content of allo5 are wit-in limit Ii.e. it2s MK. If bot- tests gi3e wrong results t-en do ridigas operation in gas test . mi9 c-emical components in case of c-emical test.

-ie Preparation 1-e casting of piston is actuall5 done b5 die'casting. 1-e die is most important part of process because t-e final s-ape of piston is finaliEed b5 t-e die. So it is important t-at t-e die use is accurate wit-in limit. 1-e die material s-ould wit-stand at -ig-er temperature.

;irst Pie/e ppro%al fter setting t-e die, production is not startedO first one or more sample piece is casted . is c-ec)ed . 1-e5 are tested for all dimensions, -ardness, etc. . if t-e5 are appro3ed t-en t-e production is started ot-erwise t-e production is repeated or necessar5 actions can be ta)en.

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Menon Pistons Limited, Plant II, MIDC Kupwad

Parting, ;elting > (torage of /asting During casting, runners . risers are pro3ided along witot-er necessar5 pro;ections. 1-ese pro;ections re4uired to be remo3ed w-ic- is done in parting . felting operation. fter t-is pistons are stored in round buc)et . t-en transferred to furt-er operations.

*eat Treatment 1-e casting produced is -a3ing lower -ardness. 8e re4uire -ardness up to ?A &#(. $or t-is purpose t-e -eat treatment is done on casting. t first solution treatment is done at +GA to +>A NC in pit t5pe electric furnace. 1-en t-ese pistons are 4uenc-ed in water to a3oid soft spots due to bubble formation w-ile castings are rapidl5 dipped in . out in water. fter solution treatment . 4uenc-ing, t-e precipitation treatment is done on casting. $or t-is purpose t-e furnace =sed in bo9 t5pe, electricall5 -eated furnace. 1-e temperature ac-ie3ed is 1GA'<AA NC . duration is J -rs. precipitation treatment we get re4uired -ardness i.e. up to ?A &#(. fter t-e

1ransfer to piston storage '

1-e stored castings are transferred to mac-ine s-op as per t-eir sc-edule date.

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Menon Pistons Limited, Plant II, MIDC Kupwad

PI(T2N M :*IN4 (*2P PR :TI:4( ;oundry

1-e foundr5 is t-e beginning of t-e piston. t t-e foundr5 t-e die is

prepared b5 -eating it to operating temperature for appro9imatel5 one -our. 1-is process allows t-e die to readil5 accept t-e molten material w-en it is poured.

$ig. Pouring of molten metal in die

T$e die
1-e dies used are ? pieces and t-ree pieces. 1-ese dies are made from cast iron wit- steel inserts for t-e gudgeon pin -oles and t-e cores. 1-e cores dictate t-e placement of t-e gudgeon pin and can be located to gi3e offset pins or s4uare pins.

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Menon Pistons Limited, Plant II, MIDC Kupwad

$ig. Die

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Menon Pistons Limited, Plant II, MIDC Kupwad

T$e pro/ess
1-e process starts b5 -eating t-e material to JAA degrees Celsius. 1-is is well abo3e t-e melting point of t-e aluminum, but below its boiling point. 1-e material is t-en scooped up wit- a ladle from t-e crucible It-e pot t-at -olds t-e molten materialK. 1-is is t-en poured into t-e die t-roug- t-e spur. 1-e material is t-en allowed to cool before it is remo3ed from t-e die and placed into a bin of -ot water. 1-is water is used to facilitate a more e3en settling of t-e -ot metal. fter t-e castings -a3e -ad time to cool t-e5 are placed into a -eat treatment plant o3ernig-t. 1-is process tempers t-e casting and ensures t-e piston will -a3e impro3ed 4ualities. fter it is remo3ed from t-e -eat treatment t-e casting -as its runner remo3ed. 1-is process ta)es little time and is full5 automated.

$ig. Cutting e9tra pro;ections

Pin Boring
t t-is stage of t-e piston manufacturing process t-e casting -as t-e gudgeon pin -ole roug- mac-ined and t-e locating bung mac-ined. 1-e bung t-is process is w-ere t-e casting is mac-ined on t-e base to allow placement of t-e casting in ot-er mac-ines. 1-is is carried out on a simple lat-e.

1+

Menon Pistons Limited, Plant II, MIDC Kupwad

$ig. Pin boring Pin boring is done in con;unction wit- t-e bung turning, as one casting is remo3ed from -a3ing t-e bung face mac-ined it is placed on t-e pin borer. 1-e pin borer is onl5 a roug- mac-ining process w-ic- allows t-e reamer to enter t-e gudgeon -ole later.

:N: Turning
1urning of t-e casting is carried out on C!C IComputer !umeric ControlK mac-iner5. 1-is e4uipment is t-e most accurate and fastest a3ailable for t-is application wit- 3er5 tig-t tolerances and e9tremel5 fast spindle speeds. 1-e castings are placed in t-e lat-e on a bung and -eld in place b5 a solid rod t-roug- t-e gudgeon pin -ole. draw bolt is acti3ated in t-e c-uc) w-ic- draws t-e rod toward t-e c-uc) and -olds t-e piston in place.

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Menon Pistons Limited, Plant II, MIDC Kupwad

$ig. 1urning 1-e lat-e is t-en started and t-e mac-ining c5cle begun. 1-is c5cle is programmed into t-e lat-e in a basic language called B'Code It-is code is not t-e onl5 one a3ailableK. B'Code -as basic commands to tell t-e lat-e to mo3e to certain positions IC, ", L co'ordinatesK, at particular spindle speeds Ie.g. S<?AA means spindle speed <?AArpmK, at particular feed rates Ie.g. BA1O rapid tra3erseK and ot-er commands suc- as MA1Irepeat programmedK and ot-ers. s 5ou can see t-is is a simple s5stem to learn and implement. ItopK of t-e piston. fter t-e piston is mac-ined it is remo3ed from t-e lat-e and t-e part number stamped on t-e crown

fig. Broo3ing 1-e piston is now read5 for t-e finis-ing processes. 1-e first stages of t-e finis-ing process include drilling, slotting, 3al3e and cran) relie3ing.

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Menon Pistons Limited, Plant II, MIDC Kupwad

-rilling
Drilling includes all oil -oles in places suc- as t-e gudgeon pin bosses and oil ring groo3es. Slotting is w-ere slots are placed in t-e s)irt or in t-e oil ring groo3e.

"al%e relie%ing
1-is process is done on a mill and in3ol3es setting t-e mac-ine up for t-e process, c-oosing t-e correct cutter and completing t-e ;ob. Since t-ere are so man5 different t5pes of 3al3e relief2s it is impossible to -a3e a specialiEed Mac-ine set up to do one ;ob.

:ran! relie%ing
Cran) relie3ing is carried out on a specialiEed mac-ine w-ic- scallops t-e s)irt of t-e piston to t-e re4uired s-ape and dept- b5 using two opposed cutters Placed on a common s-aft.

6rinding

$ig. Brinding 1-is process in3ol3es t-e final siEe being mac-ined on t-e piston. 1-e grinder mac-ines t-e s)irt of t-e piston onl5 and in t-e ma;orit5 of cases is cam ground. Cam grinding ensures t-e piston will PgrowP e3enl5 in t-e bore of t-e engine.

1J

Menon Pistons Limited, Plant II, MIDC Kupwad perfectl5 round piston will e9pand une3enl5 during use because of t-e une3en placement of material in t-e casting Igudgeon pin bosses and ribbing used for strengt-eningK.

6roo%ing 1o locate t-e piston rings on t-e piston t-ere is need to formation of groo3es. 1-ese groo3es are formed in two successi3e operations as roug- groo3ing . finis- groo3ing. 1-is groo3ing is of 1 to + or more in number depending on design . re4uirement of piston.

-is$ing ?

fig. piston after dis-ing Dis-ing is not-ing but to pro3ide t-e ca3it5 in uppermost rigid portion of piston, w-ic- is useful to increase t-e displacement i.e. cc. suc- dis-ing is also done in two stages.

;orm Turning Suc- operation is called cam or cop5 turning. In suc- operation a masterpiece or cam made of wear less material . follower made of fiber are used . connected wit- turning tool b5 spring . connections.

Reaming
1-is operation is done for lubrication purpose. Suc- t5pe of drilling is perpendicular or inclined to t-e piston a9is depending on re4uirement of piston . design. 1-is operation is done as per re4uirement t-at some pistons re4uire a single -ole w-ile some re4uire a double -oles parallel .one below ot-er.

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Menon Pistons Limited, Plant II, MIDC Kupwad

fig. #eaming 1-e final mac-ining process for t-e piston is t-at of reaming. 1-is process in3ol3es t-e piston being placed in a bat- of oil and reamed at different siEes to reac- t-e final siEe re4uired. Since t-e pin boring process is onl5 roug- it is necessar5 to ream t-e pin bore a number of times to ac-ie3e t-e surface finis- and siEe re4uired.

:ir/lipping Circlipping is done for well fitting of t-e pin in bore. contact wit- t-e piston bore . groo3e is made on bore. and an5 ot-er mar)ings, and t-en sent to dispatc-. small tool is fitted eccentricall5 on mac-ine spindle. 8-en mac-ine spindle rotates, t-e tool comes in t t-is stage t-e piston is cleaned, fitted wit- t-e appropriate gudgeon pin, stamped wit- t-e pistonsH o3ersiEe ctuall5 in t-is operation t-e s-ape of cam is gi3en to wor). 1-is s-ape is li)e tapered . pro3ides o3alit5. So t-at to a3oid ;amming of piston inside t-e c5linder during e9pansion at time of combustion. &ence in t-is s-ape t-e O.D. is ma9. pin bore -ole. t open end . perpendicular to

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Menon Pistons Limited, Plant II, MIDC Kupwad

$ig. Circlipping

Burnis$ing It is super finis-ing operation. &ere t-e rollers mounted on spindle s-afts are act t-e tool for finis-ing bore. Kerosene is used as coolant for t-is operation. < or F microns material is remo3ed in t-is operation.

1in Plating '

During t-is operation first anodiEing is done . t-en after tin plating is done. (5 performing t-is operation we pro3ide t-in plating of tin on piston as per our re4uirement. =suall5 t-is t5pe of plating is done for KO%L, #OCK%1, . B#%%/%S pistons. $or anodiEing t-e solution contains0 8ater Q sulp-uric acid Q o9alic acid 1-is o9alic acid is used to maintain t-e temperature of solution. done for KO%L pistons . in t-is acetic acid is used is solution. %.g. 1 1 pistons are coated wit- grap-ite powder . t-en -eated. lso plating is

Dispatcfter cleaning, inspection, . punc-ing t-e pac)ing . dispatc-ing is done . send t-e piston storage.

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Menon Pistons Limited, Plant II, MIDC Kupwad

: (4 (T3-<
*4 T TR4 TM4NT 2; PIN &eat 1reatment is t-e controlled -eating and cooling of metals to alter t-eir p-5sical and mec-anical properties wit-out c-anging t-e product s-ape. &eats 1reatment is often associated wit- increasing t-e strengt- of material, but it can also be used to alter certain manufacturabilit5 ob;ecti3es suc- as impro3e mac-ining, impro3e formabilit5 and restore ductilit5 after a cold wor)ing operation. 1-us it is a 3er5 enabling manufacturing process t-at can not onl5 -elp ot-er manufacturing process, but can also impro3e product performance b5 increasing strengt- or ot-er desirable c-aracteristics. Steels are particularl5 suitable for -eat treatment, since t-e5 respond well to -eat treatment and t-e commercial use of steels e9ceeds t-at of an5 ot-er material. Material used for pin is low carbon steel rod. In t-is industr5, t-ese rods are cut . bored in re4uired siEe from ot-er factor5. (ecause of carbon M in steel rod about A.<M s-ows propert5 li)e softness, ductile, malleable, -ardness of pin is 1<A'1+A (&! . tensile strengt- is +<A'+?A M!:m<.8e re4uired -ardness from gudgeon pin is about ?G',? &#C. So it goes for following -eat treatment process.

:ar#uri@ing8
1-e met-od of increasing t-e carbon on t-e surface of steel is called as CarburiEing. It consist of -eating t-e steel in austenitic region in contact witcarburiEing medium, -olding at t-is temperature for a sufficient period in austenitic region ,t-e solubilit5 of carbon is more and -ence t-e carbon from medium diffuse into t-e steel i.e. in t-e austenite. &ig- carbon content on surface does not mean -ig- -ardness of surface, unless t-e carbon is present in t-e Martensitic form. &ence after carburiEing -ardness treatment is necessar5 to bring carbon in t-e Martensitic form.

Pro/edure8
1-e pins are wired on t-e plate fi9ture. 1-e load contains 1GA pins t-e load is placed in pit furnace. 1-e furnace is -eated b5 electrical coils I+ coilsK.1-e temp of furnace is maintained at >1?NC. 1-e load is )ept about ,-rs.in t-e furnace for carburiEing acetone and met-anol is used. 1-e met-anol is used to create <1

Menon Pistons Limited, Plant II, MIDC Kupwad en3ironment and acts as carrier gas. 1-e acetone gi3es t-e carbon and nitrogen. 1-e carbon is pressuriEed on pins at a pressure of 1A'<A bar. 1-e nitrogen is lig-t in weig-t so it comes at top, w-en it comes out from furnace t-e nitrogen is con3erted into water droplets w-ic- are not desirable so nitrogen is burn in flame.

$ig. pit furnace 1-e temp of furnace is >1?NC so t-ere is c-ance to -eat t-e top portion of furnace. $or t-is water cooling ;ac)et is pro3ided at t-e top of furnace. &ence bottom portion of furnace is -eated and top portion is cool. 1-e caps of furnace -a3e a special arrangement in w-ic- one piston pin is placed w-en load is )ept in furnace. 1-is -elps to test w-et-er t-e proper carbon la5er is formed or not rat-er to remo3e w-ole load single pin is tested t-en load is remo3ed.

-iffusion8
fter carburiEing t-e carbon la5er formed on t-e pins is not uniform. 1o ma)e t-e uniform la5er of carbon t-e pressure is reduced to Eero. 1-e diffusion is carried out for <-rs. 1-e temp is >1?NC same as carburiEing.

*ardening8
1-e -ardening is carried out at G+ANC. 1-e soc)ing time is FAmin. (asic steps in &ardening0 1o -eat steel to some temperature abo3e it2s transformation point so t-at it becomes entirel5 austenitic in structure. 1o 4uenc- t-e steel at same rate faster t-an critical rate to produce Martensitic structure.

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Menon Pistons Limited, Plant II, MIDC Kupwad Ma9imum temperature to w-ic- a steel is -eated before 4uenc-ing to -arden it is called -ardening temperature. 1-is temperature depends on C-emical composition. mount of e9cess ferrite.

Ma9imum grain siEe permitted.

&ardening in salt bat-0

$ig. salt bat- furnace Molten bat- of 3arious salt mi9ture are used e9tensi3el5 for -eat treating operation. Commercial salt bat- mi9ture are a3ailable t-at meet a wide range of temperature . ot-er metallurgical re4uirement. (at- ma5 contain mi9ture of sodium, potassium, . calcium c-loride or nitrates sodium, potassium, calcium in 3ar5ing proportion to w-ic- sodium carbonate . sodium c5anide are added to pre3ent decarburiEation.

Tempering8
1-e ob;ect of tempering or drawing is to reduce brittleness in -ardened steel . to remo3e internal strain caused b5 sudden cooling in 4uenc-ing bat-. 1empering process consist in -eating steel b5 3arious means to a certain temperature . cooling it. 1empering is carried out in oil bat- mostl5.

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Menon Pistons Limited, Plant II, MIDC Kupwad

Procedure in -eat treatment department0 Initiall5, cutting pieces of low carbon steel bar punc-ed. Companies puncour logo, mont-, .5ear in t-e form of Mp'D',. Punc-ed pins are now -anged to rod at some distance. Suc- different rods are -anged to tra5, w-ic- is directl5 used for -eat treatment. 1-is tra5 of pin is now first carburiEed. $or w-ic- gas carburiEing furnace is used. In gas carburiEing, for production of carbon, acetone . met-anol are used, w-ic- flow is fi9ed suc- as A.,'1 lit:-r. . A.F?'A.? lit:-r. respecti3el5. #eaction is carried out at about >1A'><A degree C . carbon mono9ide is gi3en out. RC2 from RCO2 is reacting wit- R$e2 of pin. 8ater cooling s5stem used for t-is furnace time for carburiEing process is about G'1A -rs. fter CarburiEing process, tra5 of pin is cooled in coolant furnace . t-en pins goes for -ardening. fter cooling pins, t-e5 are separated . t-en t-e5 are -ardened in salt batfurnace or pol5mer 4uenc-ing. In salt bat- furnace, natural salt . sodium c5anide is used to maintain temperature. 1-e temperature of furnace is G,A'GGANC.$or pol5mer 4uenc-ing, pins carried wit-in ,Asec. in pol5mer tan). Pol5mer used for it is pol5 al)aline gl5col.1<'1GM pol5mer is used. 1-e composition of 4uenc-ing medium is0

<AM s5nt-etic oil Q GAM water

fter -ardening, produced, -ad get -ardness ,A',?(&!. fter -ardening, produced internal stress is remo3ed b5 tempering processO again tr5 of pin is placed in furnace. Depend on siEe of pin, temp. . time is maintained. $or $or 1ata2s pin' CIL pin' time S 1.?-r. . temp. S 1?A time S +-r. . temp. S <FA

fter t-is -eat treatment -ardness of pin is measure. If in case -ardness is -ig- tempering is carried . if lower -ardening is carried out. In standard room we see case dept- . core -ardness b5 RMIC#O & #D!%SS 1%S1%#2.

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Menon Pistons Limited, Plant II, MIDC Kupwad

(u#@ero treatment8
1-e subEero treatment is carried out at 'JA NC to 'GANC. Due to subEero treatment, t-e retained austenite get transformed to Martensite. If t-e 4uenc-ed steel is -eld at room temp for some time before cooling less austenite I transformed to Martensite i.e. t-e austenite gets stabiliEed. 1-ere fore, t-e subEero treatment s-ould be done immediatel5 after -ardening.

PIN M :*IN4 (*2P

fter doing -eat treatment on pin a lot of gudgeon pin stored for furt-er mac-ining in pin storage department. Menon piston produces 1GJ no. of pins of 3arious companies including &ero &onda, KO%L, Le5land +AA, and 1ata indica J?, %scort sF1<clas, #oc)et GA etc. $irst of all in introduced for Center less grinding in w-ic- e9cessi3e material up to 1AA'1?A:mu.m will remo3ed.

6rinding8
Brinding is t-e operation of remo3ing metal in t-e form of minute c-ips b5 feeding t-e wor) against a rotating abrasi3e w-eel )nown as t-e grinding w-eel.

Center Less Brinding0

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Menon Pistons Limited, Plant II, MIDC Kupwad Centerless grinding is t-e met-od of grinding e9terior c5lindrical, tapered . formed surface on wor) pieces t-at are not -eld . rotated on centers. 1-e wor) is placed upon t-e wor) rest . latter, toget-er wit- t-e regulating w-eel is feed forward, forcing t-e wor) against t-e grinding w-eel. 1-e a9ial mo3ement of t-e wor) past t-e grinding w-eel is obtained b5 tilting t-e regulating w-eel at a slig-t angle from -oriEontal. n angular ad;ustment of A to G or 1A degree is pro3ided in t-e mac-ine for t-is purpose.

1%C&!IC L SP%CI$IC 1IO!S $O# C%!1%#%L%SS B#I!DI!B M C&I!%... D%SC#IP1IO!

Brinding range diameter Brinding w-eel siEe IOD 9 8 9 I.D.K #egulating w-eel siEe IOD 9 8 9 I.D.K Ma9imum Lengt- in indeed grinding 1AA mm Ma9imum Lengt- in t-roug- feed grinding Brinding w-eel speed #egulating w-eel speed Brinding w-eel motor #egulating w-eel motor Coolant pumps motor. &5draulic power pac) #egulating w-eel ngle tilting =pper Slide swi3eling ppro9. 8eig-t ppro9. Mac-ine siEe mm. IL 9 ( 9 &K 1GAA #.P.M. <A'+A',A #.P.M. I/ariable speedK ? &P:F.J Kw 1++A #.P.M. ' FP-ase 1 &P $lange 9 1++A#.P.M. ' F P-ase A.1? &P F P-ase A.? &P $lange F P-ase ? degree F degree 1GAA )g. 1G?A 9 11AA 9 1,AA mm FAA mm 9 J? mm <<? 9 1AA 9 J,.< mm

MOD%L SL'J?
<'J? mm F?A 9 1AA 9 1<J mm

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Menon Pistons Limited, Plant II, MIDC Kupwad

d3antages of Center less Brinding0 1. s a true floating condition e9ist during t-e grinding process less metal to be

remo3ed. <. 1-e 8:P. being supported t-roug- its entire lengt- as grinding ta)es place t-ere is no tendenc5 for deflection of t-e wor) . small, fragile or slender 8:P. can be grounded easil5. F. 1-e process is continuous . adapted for production wor). +. 1-ere is no re4uirement of an5 -olding de3ices li)e c-uc), mandrel etc.

&ardness test0
fter first center less grinding pin will c-ec)ed for -ardness test, it is 3er5 important to c-ec) -ardness of t-e pin is wit-in desired limit or not. &ence in Menon Piston Compan5 t-e5 adopted #oc)well &ardness test. Since in t-is met-od, -ardness of metal is correlated wit- t-e dept- of indentation. &arder t-e material dept- of indentation for a gi3en load. d3antages of #oc)well -ardness test0 1. (rale indenter is used for testing of -ard material. <. &ardness number is obtained directl5 on t-e dial . -ence is free from personal errors. F. 1est is 3er5 fast. +. Operation needs 3er5 little training for operating t-ese instruments.

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Menon Pistons Limited, Plant II, MIDC Kupwad

Center less grinding <nd0

$ig. Centerless grindi fter completing surface g rinding gudgeon pin again tends to center less grinding <nd. It is important to pass gudgeon pin <toF times to center less grinding process to ac-ie3e desired dimensions. &ence in <nd center less grinding material up to ,AT will remo3ed.

O.D .I.D C-amfer0

It is 3er5 important to remo3e s-arp corners of pin considering strengt- of material becauseO as t-e stresses induced in pin first of all s-arp corners damaged. &ence c-amfer on t-e outer . inner diameter of pin is pro3ided. $or t-is operation speed lat-e used -a3ing different collects for -olding different pins of 3arious diameters. $eed was controlled pneumaticall5.

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Menon Pistons Limited, Plant II, MIDC Kupwad

Center less grinding Frd0

$ig. Centerless grinding s t-e O.D. . I.D. c-amfering is done gudgeon pin again tends to center less grinding Frd time to remo3e t-e material wit-in range of 1+ to +<mm. t t-is time gudgeon pins dimensions are wit-in tolerance including material w-icwill remo3e during lapping operation.

Crac) detection0
!ow as t-e center less grinding is completed it is 3er5 important to c-ec) internal defects in gudgeon pin. 1-ese defects are not possible to detect in macro inspect -ence non'destructi3e met-od is adopted for t-is purpose. &ence magnetic particle inspection met-od is used in t-is met-od special fluorescent ferromagnetic powders are applied b5 wet met-od. 1-e component is inspected in dar) room wit- ultra3iolet lig-t of wa3e lengt- between F?AA to +AAA U.

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Menon Pistons Limited, Plant II, MIDC Kupwad

Suc- a powder emits greenis-'5ellow lig-t under t-e influence of ultra3iolet lig-t . gi3es a better contrast to detect a flaw, since gudgeon pins are placed on copper rod . magnetiEed in circular met-od as current pass t-rougcopper rod for a w-ile, according to s)in effect alternati3e current I .CK flow from surface of t-e component. &ence magnetic pole is formed at t-e crac) or flaw w-ic- causes t-e magnetic powder to concentrate on t-is area . t-e flaw gets easil5 detected. 8-en flow gets magnetiEed in circular manner t-en lengt-wise crac)s are easil5 detected. If an5 defects are obser3ed in pin surface t-en pins get re;ected, . ot-er pin passing successfull5 send for furt-er operation i.e. lapping:super finis-ing.

Lapping:super finis-ing0
Lapping is t-e operation of siEing . finis-ing a small diameter -ole alread5 -ardened b5 remo3ing 3er5 small amount of material b5 using a lap. It is abrading process t-at is used to produce geometricall5 true surface, correct minor surface imperfections, impro3e dimensional accurac5 or pro3ide a close fit between two contact surfaces. In lapping mac-ine t-e laps Ipracticall5 called ad stonesK are placed in se4uence total G no laps are placed out of w-ic- last F laps are for finis-ing purpose. Laps are placed in two saddles containing + laps eac-. %3er5 lap tends pressure on t-e pin pneumaticall5. dial placed on t-e c5linders indicated pressure in eac- c5linder Iin barK.Budgeon pins are placed wit- t-e -elp of rollers. /ibration speed of laps . acceleration of rollers maintained proportional to get desired result. During lapping operation material up to A to ?T will remo3ed.

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Menon Pistons Limited, Plant II, MIDC Kupwad $or super finis-ing oil in;ected on t-e gudgeon pi w-en t-e5 roll on t-e rollers i.e.&onilo'>G1 during rec5cling oil it is filtered F times. Due to t-is oil we get -ig- 4ualit5 of surface finis- on t-e pin. 1-is is t-e last operation on gudgeon pin, after t-is operation pin are c-ec)ed under 3isual detection.

/isual inspection0
During 3isual detection pins are cleaned b5 using clot- . detected t-e defects li)e crac)s or dept- cuts on t-e surface of t-e gudgeon pin, if an5 defects are not obser3ed on t-e surface of t-e pin will get re;ected. If an5 defects are not obser3ed on pin t-en pins sends for furt-er detection in standard room to c-ec) dimensions of t-e pin are or not.

Standard room detection0

1-ese air conditioning rooms speciall5 build for c-ec)ing dimensions 3er5 accuratel5 on -ig-l5 calibrated gauges li)e surtronics FQ, air plug gauge . optical flat etc. In surtronic FQ mac-ine surface finis- of pin will c-ec)ed, pin was placed on t-e / bloc) and rotated in contact wit- t-e -oriEontal member w-ose deflection are indicated on t-e dial, since less deflection results as desired finis-ing is ac-ie3ed. Outer diameter will c-ec)ed wit- t-e -elp of air plug gauge. Pin passed t-roug- t-e circular plate as t-e pressure is applied on air 3al3e air get e9perience bac) pressure -ence t-is c-ange will obser3ed on t-e dial connected to air plug. $latness of t-e pin will c-ec)ed wit- t-e -elp of optical flat . ultra3iolet ra5s, in t-is met-od pin 3erticall5 placed on t-e optical flat plate . ultra3iolet ra5s passed from t-e area of contact t-e appearance of t-e ultra3iolet ra5 on screen will indicated t-e actual surface of t-e pin. Since t-e speed am flatness measuring c-art was pro3ided for anal5Eing t-e appearing s-ape on t-e screen during c-ec)ing.

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Menon Pistons Limited, Plant II, MIDC Kupwad

1OOL #OOM . 1OOL C#I(

In t-is department or s-op, all e4uipment re4uired for production on mac-ine is stored. 1-e5 issued as per re4uirement. In t-is s-op, no. of e4uipment li)e spigot, clamp, clamp rod, clamp pin, BO'!OBO gauges, center plate, ;ig plate, fi9ture, mandrills, locators, 3arious roug-ing . finis-ing tool groo3ing forming tool. In t-is s-op Master cam re4uired for form turning also stored.

&oriEontal Spindle, #eciprocating 1able0' Brinder0

1-e spindle of mac-ine is -oriEontal and table reciprocates. 1-is grinder is used to grind t-e s-an) of tool wit- respect to its tip Magnetic s-uc) is used to -old tool on t-e mac-ine.

1ool . Cutter Brinder0

On t-is mac-ine operation li)e s-an) radius, nose radius of tool is gi3en to tool. 1ool is fi9ed on fi9ture and fed it again, t-e cone s-aped grinding w-eel. 1-e angle re4uire is gi3en b5 fi9ture plate to tool . we get re4uired radius. $or c-ec)ing form of tool li)e a form tool used form turning. 1-e magnified s-ape is inspected on screen . re4uired s-are is obtained. 1-e magnification obtained up to 1AC. (5 using optical profile because dis-ing operation depends upon form tool.

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Menon Pistons Limited, Plant II, MIDC Kupwad

6= LI1" CO!1#OL
MPL stri3es -ard to pursue Customer satisfaction t-roug- t-eir Process Control and non destructi3e 6ualit5 c-ec)s as well as maintenance and impro3ement of t-e 6ualit5 S5stems. (5 use of rigorous 6ualit5 Standards and S5stems at 3arious stages of manufacturing wit- t-e computeriEed On'Line *Statistical Process Control. 1ec-ni4ues, MPL ensures t-at products w-ic- reac- t-e customers are defect free and -a3e been produced wit- t-e -ig-est International 6ualitati3e Standards. MPL -as been awarded and Certified b5 t-eir 3alued Customers for t-eir 6ualit5 related acti3ities and -a3e been recogniEed as t-e most @6ualit5 Conscious and Consistent7 Supplier. are practiced in all locations. In t-is department inspection as well as 4ualit5 control of piston . pins is done. Inspection . calibration of measuring are also done. In t-e inspection, sole9 pneumatic comparator wit- ring gauge is used. #ing gauge is of perfect re4uired dimension. 1-e tolerance re4uired for pins is A.AA<mm. lso taper in pin . o3alit5 of pin t-roug- ring gauge. $or calibration, 3arious mac-ines are used to calibrate 3arious instruments used for measuring purpose. 1-e5 are 3er5 accurate. appro3ed. 1-e5 are as follows0' ll Plants of MPL -a3e been certified for @ISO:1S 1,>+>7 <AA< and t-e s5stems and procedures based on 1PM, Si9 Sigma principles

Dial calibration 1ester0'

1-is instrument is used for calibration of dial gauge used in line production. 1-e dial indicator is -olding on stand 3erticall5. 1-e pointer of de3ice of instruments is touc- to st5lus of dial indicator to be c-ec)ed. 1-e instrument -a3e one dial -a3ing 3arious mar)ing or scale on it.

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Menon Pistons Limited, Plant II, MIDC Kupwad 1-e list count of instruments is A.AA1mm I1 micronK, w-ic- is 1:1A t- of L.C. of dial gauge. 1-e instrument dial is generall5 related wit- fi9ed scale . respecti3e readings are c-ec)ed on dial gauge reading, t-e reading of instrument c-ec)ed. Compared wit- dial gauge reading. 1-e dial gauge to be c-ec)ed is wit-in tolerance t-en it accepted ot-erwise re;ected.

#oug-ness 1ester Mac-ine0'

1-is is full5 automatic, surface te9ture measuring mac-ine. 1a5lor' &obson, Limited ma)es t-is mac-ine. On t-is mac-ine, part to be c-ec)ed i.e. pin is mounted. 1-e st5le w-ic- -a3ing sensor at its end is mounted. 1-e lengt- is measured is feed to mac-ine. fter some period, w-en st5lus is mo3ed o3er t-e 8e Surface of t-e pin t-e result is directl5 printed out wit- grap-. w-ic- we compare standard result.

directl5 get 3alues suc- as #a, #MS, CLS 3alue wit- t-eir respecti3e grap- from

Profile te9ture testing mac-ine0

On t-is instrument, we c-ec) t-e piston for o3alit5, taper, its diameter etc. it is 3er5 sensiti3e, w-ic- respond 4uic)l5 to c-ange. It is as simple dial indicator. 1-e piston -eld between st5lus pointer . measurements are ta)en. Pin O.D. comparator0 s discussed earlier, t-e pins c-ec)ed b5 t-ese instruments also taper, o3alit5 of pin is also c-ec)ed wit- t-e -elp of t-is de3ice. 1-e comparator used for t-is is pneumatic comparator. 1-is ring gauge is used for t-is purpose. 1-e tolerance is wit-in A.AA< mm. 1-e least count of mac-ine is A.AA1 mm. 1-e -undred M inspection is done on t-is mac-ine.

CO!CL=SIO!

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Menon Pistons Limited, Plant II, MIDC Kupwad s @Industrial Case stud57 is introduced in t-e s5llabus, its good mo3e as it will -elp t-e students to interact wit- industr5. So t-at students can get actual practical )nowledge rat-er t-an t-eoretical one. In industr5 I -a3e studied 3arious mac-ines, t-eir operations, t-eir wor)ing. It was a nice e9perience to stud5 t-e management s)ills. wor)ing aspects, problems occurring in industr5 . -ow t-e5 are o3ercome. I can conclude t-at t-e 3ocational training program pro3ides opportunit5 to learn more . more t-ings w-ic- can not be studied in boo)s. lso t-e

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