FEDERAL-MOGUL GOETZE

(INDIA) LIMITED
SUMMER TRAINING REPORT
(1/06/2019 - 12/07/2019)

PUNJABI UNIVERSITY PATIALA

Submitted By:-
Anmoldeep Singh
11703025
3ME2
ACKNOWLEDGEMENT
The internship opportunity I had with Federal Mogul Goetze India Limited was a great chance
for learning and professional development. Therefore, I consider myself as a very lucky
individual as I was provided with an opportunity to be a part of it. I am also grateful for having a
chance to meet so many wonderful people and professionals who led me through this internship
period.

I express my deepest thanks to all those who have helped me directly and indirectly throughout
the training. I choose this moment to acknowledge their contribution gratefully.

I perceive this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with all
of you in the future.
PISTON:-It is cylindrical part, which reciprocates in cylinder liner and is connected to crank
through connecting rod & transmits the reciprocating motion into rotary.

DESIRABLE CHARACTERISTICS:
1. It should be silent in operation during warming up and the normal running.
2. The design should be such that seizure does not occur.
3. It should offer sufficient resistance to corrosion due to some products of combustion.
4. It should have shortest possible length so as to decrease overall engine size.
5. It should be lighter in weight so that inertia forces created by its reciprocating motion
are minimum.
6. Its material should have a high thermal conductivity for efficient heat transfer so
that higher compression ratios may be used without the occurrence of detonation.
7. It must have a long life.
CONSTRUCTIONAL FEATURES
The top of the piston is called head or crown. Generally low cost low performance
engines have flat head as shown, In some such pistons which come quit close to the valves the
head is provided valve relief Pistons used in some high powered engines may have raised dome
which is used to increase the compression ratio as well as to control combustion. In some other
engines the piston may be specially dished to form desired shape of the combustion chamber in
its crown jointly with cylinder head. In case of a piston containing art of combustion chamber in
its crown compression ratio can be controlled very accurately but disadvantage is that in this case
much larger amount of heat had to be dissipated through the piston and the rings. Toward the top
of the piston of a few grooves are cut to house the piston rings. The left between the grooves are
known as lands . These lands support the rings against the gas pressure and guide them so that
they flux freely in radial direction. Supporting webs transmit the force of explosion directly from
the crown to piston pin bosses thereby relieving the ring groove portion of large loads and thus
preventing deformation of ring grooves.
The part of piston below the ring is called Skirt. Its function is to form a guide suitable of
absorbing side thrust due to gas pressure. The side thrust is produced due to the inclination of
connecting rod with cylinder axis. The skirt is provided with bosses on the inside to support the
piston. It must be sufficient length to resists the tilting of the piston under load. It is kept quite
close fitting in the cylinder but even then it is separated from the cylinder walls by means of
lubricating oil film for smooth running. The combustion pressure from piston crown is
transmitted to the connecting rod through the web inside the piston.The bosses form a bearing
surface for rocking motion of the connecting rod. The thick section webs also form heat path
from the piston crown to the gudgeon pin bosses and the skirt and thus have to be designed as to
avoid expansion problems.
The distance between the axis of the piston pin and the top of the piston crown is called
compression height and determines the compression ratio for a given engine.
DESIGN PARAMETERS OF PISTON
Boss distance
Bottom thickness
Circle groove distance
Diameter
Groove ground diameter
Groove axial height
Compression height
Lower length
Pin hole diameter
Skirt length
T Ring land height
TH Total Height
TL Top land height
FUNCTIONS OF PISTON
1. To convert chemical energy of fuel into mechanical energy.
2. It develops power which is converted from reciprocating motion to rotary motion
3. It acts as a carrier of piston rings i.e. if forms a movable gas light plug which in turn is
required
to seal the gases escaping from the piston crown down to the crank case.
4. It transmits the force of explosion to the connecting rod.
5. It forms a guide and bearing to the small end of the connecting rod and takes the side thrust
due to the rod.
 INTRODUCTION TO PISTON FOUNDRY
Piston Foundry Department is department where casting of all types of piston takes place,after
casting of piston undergoes machining where other design parameters of a piston is modified as
per requirement of piston such as surface finishing,drilling etc. at various departments such as
piston machining (domestic),piston machining (export)often called malden& LVD(light vehicle
diesel) depending upon type of piston then it undergoes other subsequent processes(packaging
etc.)
SUB-DEPARTMENTS AT PISTON FOUNDRY:
1.Pre melting section
2.Melting section
3.Casting sections: a) Domestic b)MLDB
c)Exports(Malden) d)FATTA Cell
4.Cutting section
5. Die repair section & maintainance setion
6. Heat treatment section
7.other secondary operations such as filing ,grinding ,BT thickness checking etc.
8.Final inspection
Process flow of a piston at piston foundry takes place this way as shown below:
Pre Melting & Melting:

Equipment used at pre melting section is PNG(piped natural gas)fired furnace. Oil fired furnace

is mainly used for melting of rejected casting runner risers and scarp from foundry and machine

shop called pre melting.PNG/OIL fired furnace is operated by burning of air and oil or LPG. It is

made in rectangular shape with refractory bricks. Oil is injected into the furnace through

nozzle,is form of fine spray. For atomization , air is supplied to the nozzle with help of blower.A

special tilting of rack and pinion type is made at side of furnace for pouring of molten alloy into

crucible.Blower is used for blowing air in nozzle, is centrifugal type, which is driven by electric

motor. Air is used for provide proper air for complete combustion.Air from blower is sent to

preheater to raise the temperature of air, which is used for burning. Due to hot air, oil will

atomize easily. Preheater takes the heat of exhaust gases of combustion thus provides proper

utilization of energy and money. Preheater is situated in the chimney of the furnace.Oil is

supplied from oil tank situated outside(! the shop through hydraulic motors. Oil is filtered with

help of filter with help of filter one before the hydraulic motor and other after the hydraulic

motor. For measurement of quantity of oil used flow meter is connected to oil supply. Pressure

reduction valve is connected for reduction in the pressure. Pressure can be measured with

pressure measurement device, which is connected to oil supply

Operation: Firstly furnace is heated with brining of cloth or wood for 10 to 15 minutes.After

that oil is supplied at low pressure and heated for 10 to 15 minutes. Then supply of oil is

increased and compressed oil is sent at a presstire when furnace becomes red hot scrap is put in

to furnace slowly. When the scrap is melted completely flux in the form of in colour of pink and

white is added and molted alloy is stirred slowly after chemical reaction of flux with impurities

slag will be formed which is lighter and comes surface of the molten metal and is driven out.
This molten alloy from scrap is known as Dubliex. In conduction furnace 75% dubliex is used

and 25% fresh alloys.The furnace is operated till tapping temp. is reached in; case it is to be

poured directly in the holding furnace. Otherwise it may be poured before tapping temp. if it is

used for dupluxing. But to be poured in holding furnace it is to be analysed for composition.

Corrective steps are taken if it is not verified and again analysed for composition verification.

Equipments used in melting :INDUCTION FURNACE

It has crucible formed from ramming refractory mass around a mild steel former. Electric power

is supplied lay an induction coil placed around the crucible concentrically, protected from heat

by refractory and insulating material.The coil is made of thick copper tube inside which cooling

water is circulated.Furnace is placed at a raised level in a platform and has tilting mechanism for

pouring liquid metal into crucible on fork lifting truck.There are Five type of induction furnace:

1.ABP Furnace

2.Pioneer furnace

3. Junker furnace

4. Piller furnace
5. Megatherm
The maximum capacity of the induction furnace is one ton and each one can provide 400kg. Of
molten metal per hour. There is a hydraulic lift provided to tilt the furnace in order to pour the
molten metal in crucible of transporting wagons. The fluid used in hydraulic lift is servo oil
grade 60.There are induction coils made of copper. There are restraining straps provided which,
hold the crucible in case of breakdowns. The induction furnaces have better temperature control
power of each furnaces 250 KW.
Principle of operation: - Induction furnace operates on the principle electromagnetic induction
effect.
System includes -Frequency converter, solid electronic device to convert the many frequency to
required higher frequency water supply, control panels and capacitor to improve power factor.
Operation -Firstly alloy number is identified which to be made for particular piston type and
identify quantity. Aluminiun and alloying elements are weighted according to work plan. Then
change is loaded into furnace crucible through overhead crane. Then switch on the control
voltage and power supply. Duplex metal from oil-fired furnace is also loaded in induction
furnace about 75%. Before tapping temperature is achieved weighted Magnesium is added into
charge. After composition analysis the required amount of alloy is tapped into holding furnace
crucible. All the information about tapping temperature, composition are recorded in daily
melting report.In the event of composition does not meet the specification, required elements of
alloy are added and furnace is run & analyzed for composition from labs.
Tilting Mechanism:Induction furnaces are situated over a raised platform so that tapping done
easily. These furnaces are tilted hydraulically by mans of hydraulic jack, which operated by
compressed oil.
COMPOSITION ANALYSIS
In induction furnace before tapping the charge into holding furnace crucible composition of alloy
is checked by the melting section.In this analysis a sample is made of the alloy which, to be
checked.
Sample is made by casting the alloy in a open die. Sample is tear off at thicker section
and sample without raiser is sent to laboratory for checking the percentage different alloying
elements.
Principle:Principle of checking percentage different alloying elements is spectroscopy.
According to this principle different element emits different wavelength of rays when in an
energized atom, electron comes from excited state to ground state. By measuring percentage of
rays of different wavelength percentage of different alloying element can be measured.Test
Machine- Emission type spectrometer
Composition Control:Different alloy number have different composition of alloying element
alloy composition is kept according to work plan. Composition controlling is main part of quality
control. If percentage of any metal is less as observed from composition analysis. Pour the
required amount of that metal and then take another sample for testing. After composition of the
alloy is approved then it is tapped to holding furnace.
Composition analysis in holding furnace:During fluxing the charge in holding furnace
percentage of Mg decreases because Mg is very reactive. Therefore a sample is taken from
holding furnace crucible and tested for composition analysis
METAL FLUXING
Furnace alloy in holding furnace, which is tapped from induction furnace has many impurities.
To remove these impurities fluxing is done. In this process flux (coverall - 11) is added to over
the surface of molten metal. It is stirred slowly until lip pink colour of the coverall - 11 changes
red colour. Coverall - 11 reacts with impurities and forms slag, which is lighter and comes over
the surface of the molten metal and is taken off.
Degassing:Since molten alloy is in contact with atmosphere, aluminum at higher temperature
has a disadvantage that it reacts with moisture present in air. Hydrogen gas is evolved during
reaction, which is absorbed by molten aluminum alloy.
3H2 O + 2 Al -------> 6H + Al2 O3
Due to absorption of hydrogen gas when alloy is used to casting the piston, it makes
small pinholes in the casting. Thus it forms a defect in casting, due to which thermal conductivity
and strength of piston decreases. To remove Hydrogen gas from the molten alloy degassing is
done.For degassing Chlorine and Argon gas is passed through the molten alloy. These gases
come in contact with Hydrogen gas and forms bubbles of comparatively big in size, which comes
out due to lesser density.
Chlorination:Chlorine is passed through the molten alloy in a holding furnace with a help of
plunger having hole at bottom. Before plunger put into the H.F., is preheated to avoid blast.
Chlorine gas is available near to each H.F. through pipeline. It is passed at a sufficient supply for
10 minutes in each H.F.
FOR ALLOY CSA-12 & 18
CHLORINATION TIME 15MIN
WAITING TIME 10MIN
FOR ALLOY CSA- 24
CHLORIN"ATION TIME 20MIN
WAITING TIME I0 MIN
ARGON (Ar) -Argon gas has same function as that of Cl2. But Argon gas is supplied by RDU
(Rotary Degassing Unit), which provides gas at a particular pressure in form of fine bubble.
Moreover it provide uniform degassing throughout the H.F. because of rotary plunger of RDU
provide gas in fine bubble throughout the H.F. and revolves the gas in the crucible.
TESTING OF GAS IN THE ALLOY
There are three types of test of checking gas present in the molten alloy.
1 . Probe mould test.
2. Metal mould test
3. VAC test
1. Probe mould test:In this method a sample is made in a brick mould, which is made of
refractory material. Molten alloy is poured into brick mould and after solidification surface of the
sample is observed. If the surface is clean and shine and have no hole on surface then alloy have
no gas.
2. Metal mould test:In this method sample is made in a metal mould. After casting sample is
sent to sample test lathe machine where sample surface is observed at various section's outer
surface, faces by cutting, facing, turning operation carried on the lathe. Lathe is manually
operated by the operator.
3. VAC test (Vacuum Test):Vacuum test is more accurate test for testing the gas is alloy. In this
test two sample of the alloy are made one in mould placed in open air (i.e. atmospheric pressure)
and another in a vacuum chamber at a pressure 80mbar.
After solidification of sample, which is placed in the vacuum is observed if there is any bubble of
metal is formed on the surface of sample, bubble is tear off. Then density of both samples is
measured on Vacuum machine. Due to vacuum, sample that is made in vacuum chamber have
lesser density. Then density index is measured.
Density index ={Datm – Dvac}*100
Datm
There is upper limit for density index as

Alloy no. Density index

124/ AC8A/138 1.2

244/AC9A 1.7

Density index should be lower than or equal to these limits.

CASTING SECTION:A casting may be defined as metal object obtained by allowing molten

metal to solidify in a mould cavity. Casting is a process of forming metal objectives by melting

metals and pouring it into mould.

In FMGIL Piston foundry, casting of Piston is done in a semi automatic die-casting machine.

The pistons are manufactured by gravity die-casting i.e. no external pressure is applied during

solidification of molten metal in the die except the head of metal in the mould.All machines are

hydraulically operated. Hydraulic pressure is obtained from hydraulic pumps that are placed

inside the shop and are connected to all die casting machines through pipes.

The casting section consists of the following equipment: 1. Holding furnace:

In foundry there are twin holding furnaces (two crucible in a single shell). Each holding furnace

has a power of 40 kw and metal capacity of 200 kgs. Heating is done by nicrome heating element

(90% Ni & 10% Cr). Heat is generated due to resistance heating i.e. when current is allowed to

pass through elements they offer resistance to the flow of current which produces heat to keep

the metal hot. Steel and graphite crucibles are used for holding of metal. Steel crucible is used

for low temperature i.e. holding 124 and 138 alloys, while graphite crucible is used for high

temp. i.e. AC9A and 244 alloys. Graphite crucible can also be used for 1245 and 138 alloys but

they comparatively more costly and have shorter life period than the steel crucible. Temperature

is controlled automatically after the setting is done. Once the temperature is achieved the & irrent

will cut off automatically and will be switched on at present temperature.

2. Semiautomatic Die Casting Machine:There are semi-automatic die casting machines, which

are in use in this foundry for casting of different pistons. Most of them are made by the FMGIL

Bangalore; some of them are made by Mahle Firm. The difference is that assembling,

disassembling and tilting of dies is all automatic. These are gravity casting machines. The
operation is hydraulic with the plunger type mechanism. The different types of die casting

machines are:

(a) DCM-9:This type of die casing machine is used casting pistons of bigger diameter i.e. above

80 dia.

(b) DCM-3This type of die casting machine is used for casting pistons of medium size diameter

i.e. from 65-80 dia.

(C) DCM-17:This type of die casting machine is used for casting pistons of smaller sized pistons

i.e. below 65 dia.

All machines are hydraulically operated. Each part can be separately operated with a switch

meant for it. In auto-cycle position all the tools are operated in a particular sequence in a cycle.

After switching foot push button, cycle starts again. These tools are drawn before parting of the

mould as soon as metal starts to solidify.

Filter: These filters are of ceramic material and are placed in the moulds in the seats made for

this purpose. The metal is filtered as it enters in the mould cavity, consequently the quantity of

the casting is significantly improved due to the removal of oxides and inclusion from the metal

stream and also eliminate the turbulent flow of metal as it flow through it.

3. Core Making:Cores are needed to provide the cavity on combustion chamber on the crown

of the Piston. These cores are made of the core sand which has the following constituents-

a. Silica sand 50%

b. Dexil 0.3%

c. Aluminum Powder 0.3%

d. Water glass and binde 5-6%

The grain size of sand of 0.05-0.1 mm. Cores are made by carbon dioxide process in which

firstly, sand is mixed in mixture and then put in the molding machine. The core box is placed on

the platform of the machine and pressurized. This puts the sand in the core box. The core box is

taken out and core box is thoroughly cleaned with- compressed air. The cores are coated with

graphite and then they are dipped in the oil mixed with some powder. After dipping the cores in

the oil they are oven for drying. The drying is done for 1. 5 hours at temperature of 78-degree

Celsius.

Chemicals used in Casting Section:Die paint , Tool paint , Sand core mixture, Core coating ,

Hot Taper Exothermic

Making of ring carrier Piston:

These types of pistons in which rings are setup at the casting time. These pistons are bigger die

pistons. They are casted on DCM 9 machines. The company has made this Piston for Tata 97 and

92 dies, Escorts 372, Sonalica and Eicher. The rings are of cast iron and imported from other

company. The surface of the rings is very plain so to make there rough surface there is a

machine, which is called short blasting machine.

Defects in Casting:

1. Blow Holes: They are smooth round holes, visible on the surface of the

casting if they are on the outer surface, they are turned as outer blow holes and

if on the inner surface, they are turned as inner blow holes.causes-gases entrappment

2. Pin holes: After machining operation, holes on the surface are termed as pin holes.Causes:

Hydrogen gas absorbed in the metal.

3.Cold Laps: If streams of molten metal which are too cold physically met in mould cavity but

do not fuse together, they develop cold lap defects.

Causes:1.Too Cold Molten Metal.2. Metal lacking fluidity.

4. Slag Holes: They are smooth depressions on the surface of casting result

from slag which enters the mould cavity.

5. Shrinkage Defects: Metal skinks as it solidifies. Cores can also be a source

of Casting defects.

6. Off Size: Cores which are not a correct size still do not produce desired casting

dimensions.

7. Inaccurate Core Assemblies: Core assemblies may be shifted or not well

fitted together causing dimensional errors.

VII) DIE REPAIR SECTION:This section mainly consists of a die repair section in which

various repairs are made on the dies. The die mainly consists of a mould, blocks core tools etc.

which are made of die steel. The block is fixed on the die by applying an electric arc welding.

Two side pins are used to form holes for gudgeon pin. There is inlet and outlet around the die

through pipes and goes put after cooling. Some times various lines are made on outer surface of

piston for cooling purposes.Cavity in the die may change its shape during to pouring molten

metal at high temperatures continuously. It is repaired by welding and then machinery according

to the requirement of shape and size.

FETTLING SECTION:Fettling is the process of removing extra part o the casting i.e. cutting

of runner, rises and cutting the pairs of Piston into single one.

Fettling is done before the heat treatment. Since function of runner and rises is only in casting

section after the casting is the only part of scrap. Running and riser after removing from casting

are sent to melting section for remelting and molten metal is used for casting again. There are

seven cutting machines out of which five are CNC cutting machines,Two of them are mechanical
operated. Conveyor belts are used to handle the scrap from cutting machine to scrap boxes. Scrap

boxes are transported to melted section for remelting of scrap. These conveyor belts are operated

mechanically with the help of electric motors.

Cutter used in cutting machine is made up of TCT (Tungsten Carbide Tip).Life of each cutter of

approx. one lac pistons.

HEAT TREATMENT

Purpose of Heat Treatment:The purpose of heat treatment is to maintain the hardness of the

Piston.

Process of heat Treatment:Heat treatment is done by electrical heated furnace. Piston are put

inside an electric furnace and start treating inside a chamber. After sometime then the

temperature of the chamber attains the required value then stop heating. But temperature is

maintained at required level of 5 to 6 hours. After that pistons are taken out and cooled in open

air.

Solutionising:Sometimes solutionising is done before the heat treatment so as to attain the heat

temperature so as to attain the high hardness.Solutionising is the process of heating the Piston

upto 500 deg. Centigrade and keep it at this temperature for own specified period of time and

then quenching in water at 40 deg. Centigrade for 10 to 15 seconds.

FINAL INSPECTION:Inspection comprises those operations, which check the quality of

casting & result in their acceptance or rejection.

Inspection follows:

1. visual Inspection: Certain types of casting defects are immediately obvious upon visual

examination of the casting. Cracking casting, blow holes, metal penetration, etc. can be

identified.
2. Dimensional Inspection: Dimensional inspection for casting involves the principle of gauging

as is applied to any machine elements. Surface plate, height & depth gauge, layout tables etc.

used in standard layout & inspection procedure may be applied to casting.

3. Metallurgical Inspection: Metallurgical inspection includes chemical analysis, mech.

Properties test, evaluation of casting soundness and product testing of special properties such as

corrosion resistance to heat treatment, strength in assemblies, surface conditions and surface

treatment