FEDERAL MOGUL GOETZE

Industrial Report

Johann Angelo Britto











Submitted to: Mr. Sandeep Singh Sandhu and Ms.
FEDERAL MOGUL GOETZE INDIA LTD. BAHADURGARH, PATIALA




Industrial Report

Johann Angelo Britto
11/23/2011

Submitted to: Mr. Sandeep Singh Sandhu and Ms. Priya Jaidka
RH, PATIALA


Priya Jaidka


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Acknowledgement

Any project is the fruitful outcome of the hard work of many. Through this report I would
like to express my gratitude towards those whose support and co-ordination have been an
essential ingredient of this project. I would like to say that it was a great pleasure and
privilege to have got the opportunity of visiting Federal Mogul Goetze Ltd. I would like to
thank my faculty in-charge Mr. Sandeep Singh Sandhu, Ms. Priya Jaidka for
accompanying me during the industrial visit and Mr. Prabhjot Singh Nanrey, Co-ordinator
of MET-AM, for initiating such a visit.
I am sure the knowledge and experience gained during this visit will be of immense valu for
my growth in the field of Mechanical Engineering.



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Contents


Company Profile


Goetze India Limited


Introduction to Various
Departments


Introduction to the Plant


Introduction to Piston Rings


Piston Rings Information at Federal
Mogul Patiala


Conclusion



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9



12


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Company Profile

Federal-Mogul Corporation is an innovative and diversified $6.2 billion global supplier of
quality products, trusted brands and creative solutions to manufacturers of automotive, light
commercial, heavy-duty and off-highway vehicles, as well as in power generation, aerospace,
marine, rail and industrial. The 45,000 people of Federal-Mogul located in 35 countries drive
excellence in all they do.

Our globally-networked engineering and technical centres in the U.S., Europe and Asia
enable us to bring to our customers breakthroughs in advanced technology and innovation.

We are a premier supplier of products, services and solutions to original equipment
manufacturers that use our quality components in their vehicles and automotive systems, and
to aftermarket customers who sell our world renown brand-name replacement parts through
repair shops and retail outlets. We partner with a global network of suppliers whose
commitment to excellence and on-time delivery is crucial to our success.

For more than a century, we have developed the innovative products our customers need to
produce the next generation of vehicles. Now, as we write the history of our next 100 years,
we continue to build on our position status as a market leader in product and service solutions
to set ever higher standards and continually exceed customer, shareholder and employee
expectations.
Federal Mogul Corporation
Founded in 1899 as the Muzzy-Lyon Company.
Headquarters are in Southfield, Michigan, USA.
Jose Maria Alapoint, President & CEO
Revenue $6.9 billion USD(2008)
Net Income $468 million USD (2008)
Employees: 43,000 (2008)
Website: http://www.federalmogul.com/




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GOETZE (INDIA) Limited
THE BEST WAY TO PREDICT THE FUTURE IS TO CREATE IT
The Escorts Group, with Escorts Limited as its H.P. Nanda & Rajan flagship company is
among India's largest (1917-99) Nanda corporations operating in the diverse fields of Agri
machinery , telecommunications, information technology , healthcare, bi- wheelers,
construction & material handling equipment, automotive & railway ancillaries and financial
services. The Group has 19 modern manufacturing facilities & an extensive marketing
network spread across the country .The major global alliances of the Group include: JCB -
UK, Yamaha -Japan, Claas, Mahle and Goetze - Germany, Carraro -Italy, Long CA, Vistaar
& i2 -USA, First Pacific -Hong Kong, IFS -Sweden and POL-MOT -Poland. The genesis of
Escorts goes back to 1944 when two brothers, Mr. H. P. Nanda and Mr. Yudi Nanda
launched a small agency house, Escorts Agents Ltd. in Lahore.
The next 50 years saw Escorts surge ahead and become one of India's largest conglomerates.
On assuming the Chairmanship of the Group, in Apri11994, Mr. Rajan Nanda, undertook a
major restructuring programme to give sharper focus to the businesses. This involved
building alliances with global players and improving market capitalization, which resulted in
each business becoming an independent entity with defined partnerships, technology,
customers and business economics. The recent past -also witnessed a major shift in Escorts'
business focus, when it broke away from its traditional identity of being a purely engineering
company and made its foray into the service sector of telecom and information technology
.The Group has since re- evaluated its focus with thrust on areas of high growth, namely Agri
machinery, telecom, software .
Federal-Mogul Corporation
Goetze (I) Limited has so far setup five plants in the different regions of India. These Plants
are named according to the name of the cities in which they are placed. The names of the
plants are as under: -
Alwar Plant
Bangalore Plant
Bhiwadi Plant
Patiala Plant
Faridabad Plant.
The PATIALA PLANT OF Federal- Mogul Goetze (I) Ltd. is located in the north of India
about 250 km from the capital - New Delhi and production at this plant started in 1957. It is
connected by road and rail routes. This Plant is largest manufacturer of Pistons in North-
India.


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Federal Mogul, Goetze India Limited Bahadurgarh, Patiala was set up in 1954 with the
collaboration of M/S Goetze Werke, Germany which started its production of piston rings for
automobile industry in 1957. Considering the need of complete piston assembly Escorts
Limited ventured into the manufacturing of pistons in 1958 with the collaboration of M/S
Mahle, GmbH Germany, which delivered the pistons in 1960.
Escorts entered in collaboration with M/S Suko GmbH, Germany for piston pins in 1967 and
manufacturing started in 1968.
To meet the increasing demand of market in 1977 a parallel unit for manufacturing piston
rings was set up in Bangalore.
Established in 1954
22000 employees
20 plants in all
Headquarters in Delhi
Pride of establishing the first dealer networking in the country.
Collaboration with Goetze of Germany.
Production of 1
st
class piston rings
Collaboration with Mahle of Germany
Tractor plant in Faridabad
Federal Mogul and its Products
Federal Mogul Limited is one of the biggest private concerns in India, which manufacturers a
variety of products like pistons, gudgeon pins, rings, sleeves and cylinder head. Its present
Chairman is Mr. Anil Nanda.
Products of Patiala Plant
Pistons
Piston rings
Piston pins
Cylinder Liners
Cylinder Heads
Brackets
Shocker tubes
MAIN COMPETITIORS
India piston
Usha piston
Menon piston
Samkrig
Pargeet Circle


MAJOR CUSTOMERS OF GOETZE
PASSENGER CARS AND GEEPS:
Hindustan Motors
Mahindra and Mahindra
Fiat India Limited
Monto Motors
BI WHEELERS:
Escorts Yamaha Motor Ltd
Escorts Automobiles Ltd
Bajaj Auto Ltd
Kinetic Engg. Ltd
TVS Suzuki Ltd
Majestic Auto Ltd
Scooters India Ltd
Idea Java (I) Ltd
Royal Enfield
LML Ltd
TRACTORS:
Mahindra and Mahindra Ltd
Eicher Tractor Ltd
Escorts Ltd
Escorts Ltd (Farmtrac division)
HMT Ltd
Swaraj Engines Ltd
International Tractors Ltd
Standard Tractors Ltd
New Holand Ltd
VST Tillers Ltd,Harayana tractors

COMMERCIAL VEHICLES:
Telco
Swaraj Majda Ltd
San Engg. and Locomotives
Tata Cummins

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CUSTOMERS OF GOETZE
PASSENGER CARS AND GEEPS:
Hindustan Motors
Mahindra and Mahindra
Escorts Yamaha Motor Ltd

ra and Mahindra Ltd
Escorts Ltd (Farmtrac division)
International Tractors Ltd
New Holand Ltd
Tillers Ltd,Harayana tractors
Telco
San Engg. and Locomotives


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COMPRESSION / AIR CONDITIONING:
Elgi equipments Ltd
Voltas Ltd
Sunaram Clayton Ltd
Frick India Ltd
Telco
Gabriel India Ltd
STATIONARY ENGINES
Kirloskar Engines Ltd
Ruston Oil engines Ltd
Greaves Lombardine Ltd
Indian Railways
Southern Agro Engines Pvt. Ltd
Patel Field Marshal
Sandam Vikas ( India ) Ltd
L & T Komatsu Ltd

Environment Policy
Our primary responsibility is to maintain environmental friendliness in pursuance of this
effort.
We commit ourselves
To strive continually to protect and promote environment.
To provide top priority to conserve valuable resources and to introduce technologies,
process/material that are environmental friendly.
To adhere to the spirit of continual improvement by setting/reviewing objects and
targets periodically.
To prevent pollution, reduce waste and enhance companys image.
To create and imbibe awareness towards cost effectiveness and environment friendly,
safety conscious and socially accountable measures
To comply with all applicable legal and regulation requirements.






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Introduction to Various Departments
Following department serves centralized for three plants i.e. Mahle Suko and Goetze.
SECURITY WING:
To keep safe the property of the company from thefts and fire and also check the entry of the
unauthorized persons to avoid any miss-happening in factory premises.
PERSONNEL DEPARTMENT:
This department is to maintain personnel files of all workmen up to personnel engineer level,
about their interest in work, behavior and obedience. This department also deals with labour
court cases. The personnel department is divided into following sections:
Time Office
Training and Development
Administrative
LOCAL PURCHASE CELL:
This department is to purchase item from the local market against purchase requisition to
meet day to day requirement of most urgently needed items of all the departments. In case of
any emergency during machinery breakdown, this department is to act swiftly to minimize
breakdown.

IN COMING INSEPCTION
Anything purchased from market or directly received from supplier is subjected to 100%
inspection as per the prescribed norms. Defective material is sent back to supplier.




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MATERIAL STORE:
This is the place where all the consumables items purchased or directly supplied by the
suppliers are stored in a systematic way on the racks. All racks are properly categorized. This
department receives purchase requisition from the department and pass on to the purchase
cell for action.
FINANCE DEPARTMENT:
This department is to maintain all types of account books concerning with finance and to
disburse salary to the workmen, junior staff and to release payments to the outside parties.
There is another cell with in this department, which works out the costing data of the product
that o he piston pins, rings and informs the marketing department for the finalization of the
products price with the customers.
HR DEPARTMENT:
To record the entry and departure of the workers and other junior staff members by punching
their attendance cards also maintain their leave records.
ORGANISATIONAL OBJECTIVES
PRIMARY OBJECTIVES:
a) To create and distribute the products.
b) To satisfy personal objectives of the members of the organization as
Profit of owners.
Salaries and other compensation for other objectives.
Wages and other compensation for the employees.
Physical income for all the including :
Pride in work
Security
Recognition
Acceptance
c) To meet community and social obligations as:
Protection and enhancement of human resources of society.
Protection and enhancement of the physical resources of society.
SECONDARY OBJECTIVES
To create and distribute a product.
To earn profit.
Protection and security to its workers.
Safety for its workers.
To meet social obligations.
Economy of operations by lowering cost.


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Ensure a good quality system.
Training and development of existing workforce.
To satisfy customers.
Better management.
Better human relations.
Economy of operation in meeting the primary objectives.

MAJOR LOSSES:-
Breakdown Losses.
Setup & Stoppage Losses.
Tool Change Losses.
Start- up Losses.
Minor Stoppage Losses.
Speed Losses.
Defect & Rework.
Shutdown Losses.
Management Losses-Waiting.
Motion Losses.
Line Organization Losses.
Distribution Losses.
Measurement & Adjustment
Losses.
Energy Losses.
Die, Jig & Tool Losses.
Yield Losses




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Introduction to the Plant
There are various Departments in the company, which are as follows:
Training Department (Time Office)
Pin Plant
Piston Machine Shop 1
Piston Machine Shop 2
Piston Foundry Shop
Finished Article Store (Pistons)
Tool Room
Compressor House
Generator Room
Ring Foundry Shop

The major machines installed in this plant are discussed as follows according to the products
manufactured:
Piston Ring Foundry and Machine Shop:
1. Induction furnace
2. Sand Mixer
3. Heat treatment furnaces
4. Imported besley double disc face grinders
5. Imported grinders
6. Cam turning machines
7. Slotting machines
8. Rotary baths
9. Automatic phoshating plant
10. Vertical lapping machines
Pistons Foundry and Machine Shop:
1. Induction furnace
2. Die casting machines
3. Heat treatment furnaces
4. Profile turning machines
5. Milling machines
6. Turning machines
7. Boring machines
8. Tin coating machines
9. Grooving machines
10. Center less grinders



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Introduction to Piston Rings
As a part of the industrial visit we were taken to the Piston Ring Machine Shop. Goetze
piston rings of OEMs and Aftermarket in India have state of the art design facilities for
products, tooling wit 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
30mm to 175 mm diameter

Goetze manufactures a wide range of piston rings for:
Bi-wheelers
Tractors
Passenger cars and SUVs
Commercial vehicles (HCVs, MCVs and LCVs)
Locomotive engines
Stationery engines
Industrial
Types of coating on Pistons:
Chrome ceramic plated rings
Molybdenum coated rings
Plasma filled rings
Semi-inlaid rings
Ferrox filled rings
Features:
Thin rings made from SG iron
Asymmetric profile rings
Specially honed chrome rings
Lower sharp edge rings
Reverse torsion rings
Conformable chrome oil
Keystone
Napier
Nitriding
Drilled hole oil ring
Interrupted cut



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Sections of Ring Machine Shop:
Ring Machine Shop is divided into the following sections:
Rough Section
Finish Section
Chrome Section (Plating)
Chrome Finish Section
Moly Section
CNC section
Coil Winding
Quality Assurance/ Inspection Department

MACHINES USED IN THE RING SHOP:
Besley/HMT Rough Grinding Machine
Kaefig (CNC) Finish Grinding Machine
DFS Finish Grinding Machine
Splitting Machine
DCT (Turning and Boring)
Gap Cutting Machine
Stamping Machine
Finish Turning Machine
Gap Sizing Machine
Coil Winding Machine
Grooving Machine
D- Slotting Machine
Notch Milling Machine
Bevelling Machine
Inside Grooving Machine
Inside Chamfering Machine
Lapping Machine
Honing Machine
ADA Grooving Machine
Side Grinder Machine
Outside Chamfering Machine
Outside Edge Breaking Machine
Profile Grinder
Tri Bath Washing
Cylindrical Grids




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Piston Ring Information at Federal Mogul, Patiala
A piston ring is a split ring that fits into a groove on the outer diameter of a piston in
a reciprocating engine such as an internal combustion engine orsteam engine.
The main functions of piston rings in reciprocating engines are:
1. To prevent leakage of the compressed and expanding gases above the piston into the
crankcase.
2. To control and provide the lubricating oil between piston skirt and cylinder walls.
3. To prevent entry of lubricating oil from crankcase to the combustion chamber above
the piston head.
4. Regulating engine oil consumption.
5. To prevent deposit of carbon and other materials (matter) on the piston head caused
by burning of lubricant.
6. To provide easy transmission of heat from piston to cylinder walls.

The gap in the piston ring compresses to a few thousandths of an inch when inside the
cylinder bore.
Most automotive pistons have three rings: The top two while also controlling oil are primarily
for compression sealing (compression rings); the lower ring is for controlling the supply of
oil to the liner which lubricates the piston skirt and the compression rings (oil control rings).
At least two piston rings are found on most piston and cylinder combination. Typical
compression ring designs will have an essentially rectangular cross section or a keystone
cross section. The periphery will then have either a barrel profile (top compression rings) or a
taper napier form (second compression rings). There are some taper faced top rings and on
some old engines simple plain faced rings were used.
Oil control rings typically are of three types:
1. single piece cast iron
2. helical spring backed cast iron or steel
3. multipiece steel

The spring backed oil rings and the cast iron oil rings have essentially the same range of
peripheral forms which consist of two scraping lands of various detailed form. The multipiece
oil control rings usually consist of two rails or segments (these are thin steel rings) with a
spacer expander spring which keeps the two rails apart and provides the radial load.
The piston might be a fairly loose fit in the cylinder. If it were a tight fit, it would expand as it
got hot and might stick tight in the cylinder. If a piston sticks (seizes) it could cause serious
damage to the engine. On the other hand, if there is too much clearance between the piston
and cylinder walls, much of the pressure from the burning gasoline vapour will leak past the
piston (a condition known as blow-by) and into the crankcase, and the push on the piston
from combustion will be much less effective in delivering power.



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Classification of Rings Processed:
1. Based on the type of ring
2. Based on the material of the ring.
3. Based on coating to be done
Based on the type of Ring:
1. Compression rings
2. Oil Control Rings
Based on the coating to be done:
1. Chrome Ring
2. Molybdenum Ring
3. Chrome ceramic plated rings (CKS)
4. Molybdenum coated rings
5. Plasma filled rings
6. Semi-inlaid rings
7. Ferrox filled rings
8. Chrome plated rings

Ring Properties:
Not lose its tangential tension at high temperatures.
Good conductor of heat
Having good wear resistant property
Maintain radial pressure distribution
Slide freely even under poor lubrication
An ideal Ring should possess the following properties:
High strength ductile iron material for extended life
Steel material for maximum durability under extreme load conditions
Phosphate coated (plain) gray cast iron rings for economy re-ring jobs
Chrome coated rings for maximum resistance to wear and scruffing
Plasma-moly coated rings for improved lubrication and seating.
Operations for Piston Rings Of Standard Material:
Rough Grinding
Finish Grinding
Double Cam Turning
Gap Cutting
Finish Turning
Gap Sizing
Notch Milling
Final Inspection


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Operations for KV1-K9 Material:
Rough Grinding
Finish Turning
o/s Edge Breaking
Gap Sizing
Gap Corner Chamfering
Mendrel Preparation
Brushing
Wet Sand Blasting
Chrome Plating
Belt Grinding


VISUAL INSPECTION
First Lapping
Gap Grinding
Barrel Honing
Finish Gap Grinding
Boring
Second Lapping
Notch Grinding
Final Inspection





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Ring Material
The choice of the material is dictated by the demand for its compatibility with the cylinder
wall and operating characteristics i.e. low tendency to break, wear and corrosion. High tensile
strength materials are required, if the engine operates under severe conditions. Material
properties:
The material must possess excellent heat and wears resisting quantities.
Elastic (or resilient) and must be sufficient to impact radial expansion and
compression which is necessary for assembly and removal of the ring.
High ultimate strength.
Material
Designation
Material
Specification
Min. Bending
Strength N/
mm
2

Modulus of
Elasticity
N/ mm
2

Material Type
Std. K1 350 85000-11500 Non heated grey cast iron
GOE - 13 K25 420 95000-12500 Heat treated grey cast iron
IKA K4 500 100000 - 130000 Heat treated grey cast iron
KV1 K9 1300 150000
Spheroidal Graphite iron
KV4 K22 1300 150000
F14 K11 650 130000 - 160000 Carbidic cast iron
STEEL KS3 1850 210000 Tempered Martensite
Features
Thin rings made from SG iron
Asymmetric profile rings
Specially honed chrome rings
Lower sharp edge rings
Reverse torsion rings
Conformable chrome oil rings
Keystone
Napier
Nitriding
Drilled hole oil ring
Interrupted cut
I-Ring with Cr plated Periphery


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Compression Rings:
This is a compression type
of ring with a rectangular
cross section with its
geometrically simple form
provides an adequate seal
under normal working
conditions.
Taper faced Rings: This
ring has a tapered running
surface which is intended to
shorten its running period.
Due to oil scrapping action, these rings are often used as an aid in the controlling of oil
consumption of an engine.
Keystone Ring: This is a compression ring with both the sides tapered and is used in those
cases when ring sticking is expected. Due to its wedge shape, any radial movement of the
ring will alter its axial clearance and thus minimize the build up combustion residues.
Internally beveled or stepped ring: Compression ring can be provided with one of its sides
beveled or stepped. This asymmetrical change in its cross section causes it to twist slightly
inwards when installed and bring its bottom edge into contact with the cylinder wall.
L-Shaped Ring: Rings with: Shaped cross section is commonly installed in 2-stroke engines
in order to improve control of gas flow through the cylinder ports.

Oil Controlling Rings:
Napier Rings: This ring can be considered as a compression rings with an oil scrapping
property. This recess in the ring causes it to twist in a manner similar to the compression ring
above such that the lower edge of the running surface makes contact with the cylinder.
Slotted Oil Control Rings: This is slotted oil ring with parallel sides and contact lands. Due
to the narrow lands of this type ring, a high unit pressure is achieved.
Beveled-Edged oil Control Ring: In order to achieve further increases in unit pressure and
thereby a better oil scrapping effect the outside edge of both lands are chamfered.



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Conclusion

Visiting Federal-Mogul, Piston Ring Machine Shop in Patiala was a fruitful experience. It
was the first time I had seen the processes involved in the manufacture of piston rings. I saw
numerous machines which I never thought existed and also learnt the functions of such
machine. The people at Federal Mogul were very friendly and have helped make my training
a success.

I observed the different steps of surface treatment, shaping and finishing of piston rings along
with the procedures involved in their coating and inspections. I am sure that the knowledge I
gained during my visit to Federal Mogul will help me in the future as I aspire to be a
Mechanical Engineer.