1.

Introduction
This report is a short description of my four week internship carried out as a component
of the BE programme. The internship was carried out within the company Perfect Alloy
Components Pvt. Ltd. (PAC) in July 2019 . Since we are interested in machining and
manufacturing process, the work was concentrated on manufacture ,machining ,design,
and inspection.

This internship report contains my activities that have contributed to achieve a number of
my stated goals. In the following chapter a description of the organization Perfect Alloy
Components Pvt. Ltd. (PAC) and their activities is given. After this a reflection on ,
functioning, and the learning goals achieved during the internship are described. Finally I
give a conclusion on the internship experience according to my learning goal.
CHAPTER 1

COMPANY PROFILE

PERFECT ALLOY COMPONENTS.

Established in 1979, Perfect Alloy Components Pvt. Ltd. (PAC), an

IATF16949:2016 certified company is the largest Indian manufacturer of
valve seat inserts and turbo charger parts for IC engines.

Known for its technical prominence, Perfect valve seats and turbo
charger parts are the First choice for major OEMs in India. PAC exports
over 45% of its production to Britain, Canada, China, Germany, Holland,
Italy, Japan, Korea, Malaysia, Spain, Singapore and USA.

1.1 Infrastructure :

 Location and area of the organization : PAC is situated near savalanga

road navulae shivamogga. It has spread over an area of 7.5 acres of land.
It has several unit/disvision like Product advancement division,
Production unit, foundry,quality control division etc.,
 Plant and machinery: PAC is equiped with material testing lab ,spectro
lab,olympus polarized for checking the microstructure. The machines
utlized as a part of PAC are Muruta Turning Machines, Ace Jobber-exel,
Mekiho vertical milling center(VMC) , computer numerical
control(CNC),turning machines, and Koyo grinding machines.
 Power Source: PAC utilizes the force for assembling the limit is 200kba
and DG-1880kb. PAC have their own generator unit with capacity of
500KVA(2) and 250 KVA(2) they are used for production lines.

1.2.PRODUCTS MANUFACTURED

1 Valve seats .

2 Turbocharger Parts.

Valve seats:
The valve seat in an internal combustion gasoline or diesel
engine is the surface against which an intake or an exhaust valve rests during
the portion of the engine operating cycle when that valve is closed. The
valve seat is a critical component of an engine in that if it is improperly
positioned, oriented, or formed during manufacture, valve leakage will occur
which will adversely affect the engine compression ratio and therefore the
engine efficiency, performance (engine power and engine torque), exhaust
emissions, and engine life.

Valve seat is a critical component in an Engine which

undergoes repetitive cycle of hammering by the valves at elevated
temperatures during functioning. As a result of this, mechanical deformation
of the valve seats is introduced by the thermal stress and strains. The result
of expansion and contraction of the material as a function of temperature, the
pressure built up during the ignition, varies and the complete ignition of the
fuel is not ensured. There arises a greater need for quantitative data
information on thermal expansion of the material at the elevated
temperatures involved during combustion.
Further the thermal conductivity of the valve seat material is equally
important which keeps the valve seat at lower temperature when the engine
is running at the optimum efficiency which ensures the heat generated in the
combustion chamber is transmitted to the water cooled cylinder head.

Further valve seats properties are influenced by the corrosion due to

chemical reaction continuously taking place at elevated temperatures near
the valve seat area. The wear resistance property of valve seat material at
elevated functional temperature also plays an important role.

Keeping in view the optimum temperature at which the engine has to

function and the type of fuel used the valve seat material is designed.

Fig.1 Valve seats of internal

Combustion engines.

They mainly manufacture 2 types of valve seats.

1.Smaller Diameter valve seat

2.Bigger Diameter valve seat.