GROUP MEMBERS

MUAAZ ALI
BSME01113094
HASEEB ZAHID
BSME01113037

PISTON
MANUFACTURING

 A Piston is a solid cylinder or disk that fits snugly

into a hollow cylinder and moves back and forth
under the pressure of a fluid (typically a hot gas
formed by combustion, as in many engines),
moves or compresses a fluid, as in a pump or
compressor.

Cycle of a piston

Intake
Compression
Ignition
Power
Exhaust

PARTS

OF

The
Crown : is the top surface
(closest to the cylinder head) of the
piston
which
is
subjected
to
tremendous forces and heat during
normal engine operation.

The Ring lands :Are the reliefs cut

into the side profile of the piston where
the piston rings sit.

Ring Groove: is a recessed area

located around the perimeter of the
piston that is used to retain a piston
ring.

Skirt :of a piston is the portion of the

piston closest to the crankshaft that
helps align the piston as it moves in the
cylinder bore.

Wrist pin boss : is a bore

that
connects the small end of the
connecting rod to the piston by a wrist
pin.

PISTON

Piston rings
A piston ring is an expandable split ring used to provide a
seal between the piston an the cylinder wall.
Piston rings commonly used include the compression ring,
wiper ring (second compression ring ) , and oil ring.
Compression ring and wiper ring
seals the combustion chamber
from any leakage during the
combustion process.
The oil ring is used to distribute and
regulate oil within the cylinder wall
and help scrape it back into the
crankcase

Material used for

manufacturing

Piston

material and design contribute to the overall

durability and performance of an engine.

Most pistons are made from cast aluminum alloy.

Cast aluminum alloy is lightweight and has good structural

integrity and low manufacturing costs. The light weight of
aluminum reduces the overall mass and force necessary to
initiate and maintain acceleration of the piston.

Piston rings are generally manufactured from cast iron or

stainless steel .

Piston Manufacturing Process

The pistons are usually manufactured
by means of
1)
CASTING
(an object made by pouring
molten metal or other material into a mould )

2)

FORGING

(Forging is the operation

where the metal

is heated and then a
force is applied to manipulates the metals in
such a way that the required final shape is
obtained

MANUFACTURING BY CASTING
1) FOUNDRY
The foundry is the beginning of the piston. Ingots of
Aluminum are heated in a furnace .
The molten aluminum is poured in a hydraulic mould .
The material is then scooped up with a ladle from the
crucible (the pot that holds the molten material). The
material is then allowed to cool .

2) DEHORNING , HARDENING

AND

MACHINING

The fresh obtained pistons are dehorned first by a

vertical milling machine

Dehorned pistons are hardened in an oven prior to

machining

Then in a lathe machine , the rough edges are cut

and a smooth profile is obtained by means of a turning
operation.

3)

CNC LATHE MACHINING

At first the skirt of the piston is finished

a.
b.
c.

After that the CNC is programmed to

Cut the ring grooves
Make an accurate bore diameter
Finish the crown

4) 5 axis VMC machining

In this machine the oil slots and pin bore is made

5) GRINDING
This process involves the final size being machined of

the piston. The grinder machines the skirt of the piston

only and in the majority of cases is cam ground. Cam
grinding ensures the piston will "grow" evenly in the
bore of the engine .

Final Inspection
At this stage the piston is cleaned, fitted with the

appropriate wrist pin, stamped with the pistons oversize

and any other markings, and then sent to dispatch.

MANUFACTURING BY FORGING
1 ) THE ROD
The piston begins as a three meter, solid aluminum
rod. The reason aluminum is used is that it's lightweight,
rust-proof, and easy to cut.
A saw then cuts the rod into smaller pieces called
slugs.

2) THE PUNCH
A punch press and dye are pre-heated while the slug moves
through an oven, heating it to 426 C as the punch press.
The slug is then removed from the oven, and placed into
the punch. The press applies 2,000 tons of pressure onto
the slug, forging it into the basic shape of a piston.
This process causes the piston to become so hot, that it
needs
an
hour
to
cool

MANUFACTURING BY
FORGING
3) The Oven
After the forgings cool down, they go through an oven
twice more. The first time is at a higher temperature, to
strengthen the metal. The second time is at a lower
temperature to stabilize it.

4) The Wrist Pin Holes and oil control holes

) A large hole is then drilled through both sides of the
piston. This is where the wrist pin will go, attaching the
piston to the connecting rod
) Oil control holes are drilled along the

5) Ring Grooves

Three ring grooves are created by a Lathe machine

5) The Milling machine

A milling machine then shaves up to a couple of
centimeters off of each side of the piston where the large
holes were drilled for the wrist pin insertion. This is to
reduce the overall weight of the piston.
Another milling machine takes some more metal off of
the area where the three rings were formed earlier,
bringing the piston one step closer to its final form.

5) Grinding
The next step involves grinding of the piston from its head to give the
crown the shape required according to the design . A lubricant is used to
cool the work piece continuously.

6) Finishing the Job

) Another lathe shaves a few more millimeters off of the
top, allowing the piston to expand when heat builds up
inside of it. Then a machine engraves model and production
information.
) A human worker then smooths out the sharp edges of the
piston created during production. The holes created for the
wrist pin are then put through a machine which smooths
them, allowing the wrist pin to fit comfortably.
) Finally, the pistons sprayed by hot, deionized water,
removing any lubricant or oil gathered through the
manufacturing process. After they're dry, they're ready for
use

DIFFERENCE BETWEEN FORGED

AND CAST PISTONS
CASTED PISTONS
PISTONS

They are affordable .

Lighter weight because of
the Aluminum alloy .
speed
It is generally used for slow
Speeds.

FORGED
They are expensive
Mostly used for high
or high rpms

QUESTIONS