About The Company:

In The Last Summer, I Choose To Do My Summer Practice, So I Did It In Iqab Fraij &
Partners Company, This Company Is Steel Specialist.

The Company Location Is In North Marka – Amman – Jordan , Also There Were Two
Sections In The Company, First One Was For Turning Steel Sheets To Make Large Pipes, Where
They Used Two Revolving Wheel To Turn The Sheets.

The Second One , Where I Did My Training, Was The Cylinder Liner Section, There Were
Only One Engineer And All The Others Were Workers, The Engineer Position Was The Production
Engineer And Actually He Is One From The Owners Of The Company.

In This Part Of The Factory There Was Two Department, First One The Oven Part, Where
They Reused The Remained Material Again, The Other One Was The Lathe Part.

In Lathe Part, There Was :

1- Two External Lathing Machines.

2- Two Internal Lathing Machines.
3- 3 CNC Lathing Machines.
4- One Machine To Cut The Material By Lathing.
5- One Milling Machine.
6- One Grinding Machine.

What Is Cylinder Liner?

Figure 1 : Cylinder Liner(Sleeve) & Piston & Piston Rings

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 Cylinder Liner Or Cylinder Sleeve Is A Cylindrical Part Made To Be Fit In
The Engine To Form The Cylinder & It Is One Of The Most Necessary Parts To
Make Up The Interior Of The Engine, Actually Each Engine Has Its Own Cylinder
Liner Dimensions.

Function Of Cylinder Liner :

1- Formation Of Sliding Surface :-
Cylinder Sleeve Serving As An Inner Wall Of Cylinder , Forming A Sliding
Surface For Piston Rings While Keeping The Lubricant In, The Most
Important Function Is The Excellent Characteristic As Sliding Surface & These
Four Important Points :
a- High Anti-Galling Properties.
b- Less Wear On The Cylinder Liner It Self.
c- Less Wear On The Partner Piston Ring.
d- Less Consumption Of Lubricant.

2- Heat Transfer:

Figure 2 : Impact Inside Cylinder

Cylinder Liner Receives Consumption Heat Through Piston & Piston

Rings & Transmits The Heat To The Coolant.
3- Compression Gas Sealing:
The Cylinder Liner Prevents The Compressed Gas And Consumption Gas
From Escaping Outside.
It Is Important That The Cylinder Sleeve Which Is Hard To Transform By
High Pressure & Temperature In The Cylinder.

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 The Cylinder Wall Is Under High Condition Of Pressure & Temperature ,With
Piston & Piston Ring Sliding At High Speeds, So In Particular ,Since Longer Service
Life Required

For The Engines For Trucks And Busses , The Cast Iron Cylinder Which Have
Excellent Wear-Resistance Properties are Only Used For Cylinder Parts.

Also, For Lighter Engines, Material Shifting From Cast Iron To Aluminum
Alloys Are Used , But As The Sliding For The Inner Cylinder, The Direct Sliding
Motion Of Aluminum Alloys Has Drawbacks In Deformation During Operation &
Wear-Resistance. For That Reason ; Cast Iron Used In The Most Cases.

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How To Make Cylinder Liner:
Cylinder Liner Usually Made From Cast Iron, Cast Iron Have A Good
Properties Such As Hardness & Thermal Conductivity , Expansion Coefficient & Has
Excellent Wear Resistance.

Table 1 : Hardness For Some Materials

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 Table 2 : Expansion Coefficient & Thermal Conductivity

To Make A Cylinder Liner There Are Many Steps In Two Sections,

Oven Section & Lathe Section.
In Oven Section, They Melt The Remain Cast Iron From Last
Operation, In Order To Reuse It Again, They Use An Electrical Oven, By
The Way We Know That When We Melt The Material, It Loses Some Of
Its Properties, So In Order To Solve This Issue They Add Some Other
Materials, Such As : Si (Silicon) ,C (Carbon) ,Mg (Magnesium) ,C
(Chromium) , The Temperature In Side The Oven Is 14500c & The Oven
Consumes 250 Kw/H.

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 Figure 3: Spoiled Cylinder

After That & While The Compound Is At Liquid State They Reshape
It To The Cylinder Form. Then Leave It For Cooling.
The They Move It To The Other Section, The Lathe Section.
In This Section There Are Many Steps,(The Steps Are In Order)
1- External Lathing: They Put The Spoiled Cylinder There, And
Stare The Lathing, Because The Spoiled Cylinder Has Very Bad
Surface, Here They Made A Step To Reshape It, In The Factory
There Was Two External Lathing Machines.

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 Figure 4: External Lathe Machine

2- Internal Lathing: Internal Lathing Is To Get Better Surface Than

The Spoiled One. There Was Two Internal Lathing Machines.

3- CNC Lathe: CNC Machine Is Always The Most Accurate

Machine, And Because The Cylinder Liner Is Important Part In
The Engine, It Has To Be Built In Very Accurate Tolerances, So
They Are Using The CNC Machines, There Were Three CNC
Machines There But Unfortunately Only One Was Working.

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 Figure 5: CNC Machine

4- Grinding Operation: They Move The Cylinders To The Grinding

Machine To Obtain The Geometry Of The Parts.

Figure 6:
Grinding Machine

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5- Honing Machine: They Use This Machine To Obtain The Inside
Surface Of The Cylinder As Smooth, It Take 1mm From The
Inside Thickness.

Figure 7 : Honing

Figure 8: Before CNC Machine

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:Conclusion
In That Period, I Have Been Saw The Lathing & Grinding Processes, And If I Add
What I Saw To What I Have Learned In Manufacturing 210, So Now I Have A Nice
.Vision About These Processes

Also, Now I Know How To Make One Of The Most Important Function In The
Engines, Also I Become Familiar With Some New Advices That I Have Never Hear
About It Before, Such As Micrometer(Micrometer Screw Gauge) & The Depth One,
.Also I Learned How To Use Them

Figure 9 : Micrometer & Depth Micrometer

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 Appendix
Figure 1 : Cylinder Liner(Sleeve) & Piston & Piston Rings :
Page 1
Figure 2 : Impact Inside Cylinder : Page 2
Table 1 : Hardness For Some Materials : Page 4
Table 2 : Expansion Coefficient & Thermal Conductivity :
Page 4
Figure 3: Spoiled Cylinder : Page 5
Figure 4: External Lathe Machine : Page 6
Figure 5: CNC Machine : Page 7
Figure 6: Grinding Machine : Page 7
Figure 7 : Honing : Page 8
Figure 8: Before CNC Machine : Page 8
Figure 9 : Micrometer & Depth Micrometer : Page 9

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