PRODUCTIVITY IMPROVEMENT IN THE MANUFACTURE OF ENGINE VALVE A Project Report Submitted

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING BY ASHOK BABU.J (10D55A0308)

Under the enviable and esteemed guidance of

Md.Faiyazuddin
Asst.Professor

DEPARTMENT OF MECHANICAL ENGINEERING

VIF COLLEGE OF ENGINEERING & TECHNOLOGY

Approved by A.I.C.T.E. New Delhi Affiliated to JNTU, HYD, A.P. #786, Himayath nagar, Gandipet X Roads, Moinabad Mandal, Ranga Reddy Dist-500075 2010-13

DEPARTMENT OF MECHANICAL ENGINEERING

VIF COLLEGE OF ENGINEERING & TECHNOLOGY

Approved by A.I.C.T.E. New Delhi Affiliated to JNTU, HYD, A.P. #786, Himayath nagar, Gandipet X Roads, Moinabad Mandal, Ranga Reddy Dist-500075 2013

Department of Mechanical Engineering

CERTIFICATE
This is to certify that the Thesis/Dissertation entitled PRODUCTIVITY IMPROVEMENT IN THE MANUFACTURE OF ENGINE VALVE that is being submitted by Mr.ASHOK BABU.J. Being Roll No.10D55A0308 in partial fulfillment for the award of Bachelor of Technology in Mechanical Engineering to the Jawaharlal Nehru Technological University is a record of bonafide work carried out by his under my guidance and supervision. The results embodied in this project have not been submitted to any other university or Institution for award of any degree. He has completed his project under the supervision of Mr.J.Gopala Krishna Rao, Manager Mfg during the period between 21.01.2013 to 04.03.2013. We wish him all success in his future endeavors. Internal Guide Md.Faiyazuddin Asst.Professor Head of the Department SHAIK KHADER BASHA, M.E. (Ph.D)

EXTERNAL EXAMINER

Principal

ACKNOWLEDGEMENTS
I wish to express my grateful thanks to Mr.J.GOPALA KRISHNA RAO, Dy.Manager (Manufaturing Head), Our Project guide for his invaluable guidance, help and encouragement during the course of work. I also special thanks to J.Bhupathi babu (Sr.Engineer, Prodn), P.Venkateshwar rao, (Supervisor), Naga raju, Bhasker reddy,(security Inspector)for help the project. I would also like to thank Mr.B.MADHAVA REDDY (HRD, Asst.Manger) & CH.Maheshwar Rao HRD, HEAD, Sr.Manager) for according permission to carry out this project and for administrative matters of the training program. I would like to express my sincere thanks to my internal guide Md.Faiyazuddin, Asst professor, Department of Mechanical Engineering who helped a lot in abstracting the data and arriving the project to an end. I also place record of thanks to Mr.SHAIK KHADER BASHA M.E.(PhD),Head of the Department,(ME) and thanks to co-ordinates and all honourable staff members who rendered all possible guidance in finishing the project. Department extending his expertise and valuable co-operation in successful fulfillment of my work. I would like to express my express my profound to Dr.P.SRINIVASA RAO, Principal, VIF Institute of Engineering and Technology for his useful suggestions during the course of our education. Above all I owe my gratitude and heartful thanks to all those who have helped directly or indirectly for findind this project successful in time. I sincerely thank to the Management of M/S RANE ENGINE VALVES LIMITED, AZIZNAGAR, and R.R.DIST for granting permission and extending facilities for successful completion of the project work.

DECLARATION

I solemnly declare that the project report work entitled PRODUCTIVITY IMPROVEMENT IN THE MANUFACTURE OF ENGINE VALVE is based on my own work carried out during the course of my study under the supervision of Md.Faiyazuddin Asst.professor, Department of Mechanical Engineering. I assert that the statements made and conclusions drawn are an outcome of my project work. I further declare that have not submitted this work for the award of any degree to any institution.

ASHOK BABU. J 10D55A0308

ABSTRACT
The major task of any company is to aim at customer satisfaction, by delivering the required quantity of quality products at quantitative prices as per committed schedule. This can be achieved by effective utilization of resources and by effective quality control procedures. Productivity may be defined as the ratio of output to input. Output means the quantity produced or the number of items produced and inputs are the various resources like men, machine, material and money. Productivity can be improved either by increasing the output for the same input or for the same output by reducing the input. Cycle time plays a major role in improving the Productivity. Cycle time is the total elapsed time from the beginning to the end of the process including both man and machine oriented operations. The project deals with Studying the existing processes of manufacturing the engine valves. Finding out the drawbacks of the process if any. Suggesting better processes to eliminate the drawbacks which will result in increase in Productivity/bottom line.

The project was carried out at M/S RANE ENGINE VALVES LIMITED at, HYDERABAD.

INTRODUCTION
In the Present work, the careful study on cycle time of head turning, face chamfering and seat turning operation on valve is carried out .These valves are manufactured by REVL for volts wagon it is found that machine is taking more time than required for single time. The reduction in cycle time is done by removing dwell time for the machine and making operation run parallel. This project is classified in to ten chapters. It gives information about NC machine and CNC machine programming the working of HEAD TURNING AND FACE CHAMFERING CNC machine on which project as been done and finding the cycle time for the machine and drawing the arrow diagram accorindingly. finally we deals with reduction of cycle time and concludes the project by giving the conclusion.

Productivity: t is defended as the ratio of output to input .out put means the quantity
produced or the number of items produced and inputs are the various resources like men,machine,material,and money. Productivity can be improved either by increasing theoutput for the same input or for the same output by reducing the input. According to European Productivity Council Productivity is an attitude of mind.It is a mentally of progress,of the constant improvement of that which exists.It is the certainty of beings to do better than yesterday and cintinuosly.It is constant adaption of the economic and social life to changing conditions. It is the continual effort to apply new techniques and methods.It is the faith in human progress According to Peter Drucker Productivity means a balance between all factors of production that will give the maximum output with thr smallest effort. The concept of productivity and production are totally different.Production refers to absolute output while productivity is a relative term wherein output is always expressed in terms of input. The production may rise without the corresponding rise in the productivity and vice versa. If the input remains the same and the production of output increases then there is rise in productivity. Productivity can be improved either by increasing the output or decreasing the input There are so many constrains involved to increase the output and the only option left is to reduce the input cost The main objective of study is to improve the productivity. The preliminary study shows that ther is an ample scope for the reduction of input cost to improve the productivity in different areas. Productvity is the key to prosperity all the coutries having higher standard of living area having higher productivity. Raise in productivity generates extra production,it reduces cost per unit and enables reduction in sales price,increased wages for workers and increased profits for the industry.

Productivity is nothing but the reduction in wastage of resources 4Ms and space, tine and building and management techniques etc. According to V.K.R. Memon Productivity implies development of an attitude of mind and constant urge to find better,cheaper,easier,quicker and safe means of doing a job,manufacturing a product and providing service. Productvitivity can be incrased by having the fullest control over the following; 1. Minimizing the wastage of materials 2. Minimizing the breakdown. 3. Minimizing the waiting on the part of men and equipment. 4. Minimizing excessive handling.

TYPES OF PRODUCTIVITY MEASUREMENT: 1. Material Productivity = Number of units produced/Cost of material. 2. Labour Productivity = Aggregate output/Amount of labour 3. Capital Productivity = Turn over/Capital employed. 4. Machine Productivity = Output/Actual machine hours utilized 5. Aggregate Productivity = Output/Land+Labour+Material+Capital+Other inputs.

Cycle time a plays a major role in improving the Productivity.Cycle time is the total elapsed time from the beginning to the end of the process including both man and machine oriented operations.It is the time taken from raw material to finished product.If cycle time reduces productivity will Increase

PRODUCTIVITY = OUTPUT/INPUT Where INPUT can be resources such as Men, Machine, Material and Money OUTPUT No of products or quantity.

About Valves:

Engine Valve is one of the main parts which are used in all IC Engines. Each cylinder in the engine has one inlet and one exhaust valve. Now a days engine are designed with multi valves viz., two inlet and one exhaust or Two inlet and Two exhaust valves which prevents air pollution and improves engine efficienc

1. Function of Inlet Valve: The inlet which operates by the action of Tappet movement,

allows air and fuel mixture into the cylinder. a) Allow incoming charge into the engine b) Seal the port without leak for remaining period c) Resistance to wear at the mating surfaces d) Good sliding surface for seizure resistance

2. Function of Exhaust valve: The exhaust valve allows burnt gases to escape from the

cylinder to atmosphere. a) Allow gases go out of the engine b) Seal the port without leak for remaining period c) Strength to with stand high temperatures d) Resistance to wear at the mating surfaces e) Good sliding surface for seizure resistance

Valve Efficiency: Depends on the following characteristics like Hardness, Face roundness and

sliding properties capable to withstand high temperature etc. As compared to inlet, exhaust valve operates at high temperature as exhaust gases (around 800 Deg C) escape through it. As it resulting in early ways and gets corrosion, austenitic steel is used for manufacture of exhaust valve and martens tic steel is used for manufacture of inlet valve. The manufacturing process involves upset and forging, heat treatment and machining (turning and grinding) and special processes like TIG welding, Projection Welding, PTA Welding, Friction Welding, Induction Hardening and Nitriding. Valve is an important part in IC Engines. The Fuel performance is depends on valve. The air fuel mixture in and Exhaust gases out was operated by valve.

Cotter pin Guide Cylinder

Spring

Rocker arm

Push rod

Tappet Valve

Cam shaft

The Basic Requirments for a good Valve

1. 2. 3. 4. 5. 6. 1.The material should possess good hardness. It should shock resisting material . It should be able to withstand high temperatures. A valve must be chemically inert at high temperatures. It should be wear resistant . It should be designed and manufactured properly to increase the efficiency of the engine

BRIEF SYNOPSIS ON ENGINE VAULVE:-

Values are used to control gas flow to and from cylinders in automotive internal combustion engines. The most common type of valve used is the poppet valve.The valve itself consists of a disc shaped head having a stem extending from its center at one side. The edge of the head on the side nearest the stem is accurately ground at an angle usually 45 degrees,but sometimes 30 degrees,to form the seating face.When the valve is closed,the face is pressed in contact with a similarly ground seat. The two main types of internal combustion engine are;spark ignition (SI) engines (petrol, gasoline, or gas engines), where the fuel ignition is caused by a spark and compression ignition(CI) engines(diesel engines), where the rise in pressure and temperature is high enough to ignite the fuel. Valves are used in these engines to control the induction and exahaust processes. Both types of engine can be designed to operate in either two strokes of the piston or four strokes of the piston. This details the position of the piston and valves during each of the four strokes. Induction Stroke: The inlet valve is open. The piston moves down the cylinder drawing in a charge of air. Compression Stroke: Inlet and exhaust valves are closed. The piston moves up the cylinder. As the piston approaches the top of the cylinder (top dead centre -tdc).In engines utilizing direct injection(DI) the fuel is injected towards the end of the stroke. Expansion Stroke:Combustion occurs causing a pressure and temperature rise which pushes the piston down. At the end of the stroke the exahaust valve opens. Exahaust Stroke; The exhaust valve is still open.The piston moves up forcing exhaust gases out of the cylinder.