Internship Report- Atlas Engineering

ATLAS ENGINEERING

Atlas Engineering Piston Machine at a Glance

Submitted By:
Muzammil Aslam

Rizwan Abdullah

Muhammad Kamran

Mechanical Engineering (Graduation Year 2022)

NED University of Engineering and Technology
 Internship Report-Atlas Engineering

Acknowledgement

Alhamdulillah, First of all I would like to thanks ALMIGHTY ALLAH as finally completed my
Internship at ATLAS Engineering for which I am thankful to them as well. I would like to
acknowledge the staff & management for their support and assistance with this internship.I
sincerely thanks to Mam Natasha,HR for letting me intern in ATLAS Engineering.

I would like to express my heartiest gratitude to my mentor Sir Ata, as he supervised and advised
us throughout the internship and utilizes his time on guiding and training us.I take this
opportunity to express my profound gratitude and deep regards to ATLAS Engineering staff for
their exemplary guidance, monitoring and constant encouragement throughout the course of this
Internship. The blessing,help and guidance given by them from time to time shall carry me a long
way in the journey of life on which I am about to embark.I am obliged to staff members of Atlas
Engineering, for the valuable information provided by them in their respective fields. I would like
to thank my beloved friends as well that always stick together till the end of the internship and
also worked hard to produce a good assignment with responsibility.

During the internship, I visited various departments of Atlas Engineering where I collected the
necessary knowledge of operation of these departments.
It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to the
head of those departments for their careful and precious guidance which were extremely valuable
for my study both theoretically and practically. 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 in order to attain desired career objectives.

All my regards and respect to all of the above mentioned.

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 Internship Report-Atlas Engineering

Company’s Profile

Atlas Engineering

The foundation of the Atlas Group was laid in 1962 with the establishment of Shirazi
Investments (Pvt) Limited with a capital of half a million rupees and three men doing business in
trading shares and real estate.

The Group strategic direction is determined by the Group Executive Committee while each
company functions autonomously within the framework of the predetermined policy.

Atlas Engineering has State-of-the-art facilities to produce Cast Iron process Pig iron and
Aluminum alloys through various stages into high precision Automotive components and has full
access to technical know-how and back-up of world renowned manufacturers like the Shindengen
Japan,F.C.C. Co. and Honda Foundry Japan.

The Company manufactures diesel pistons, piston pins, cylinder liners/sleeves, motorcycle
pistons, cylinders, CDI & Regulator, Pressure Die Casting, Aluminum Components,Radiator
assemblies and radiator cores and a host of fully-machined cast Iron parts (both grey and
ductile).Atlas Engineering products are comparable with hose of any International manufacturer and
as such are also exported.

The facilities at Atlas Engineering have been extended and modernized steadily over the last
decade, and are amongst the best in the engineering sector of the country. As old machines are
phased out, new machines including CNCs, and semi-automatic machining lines are being added.
Further expansion of facilities for manufacture of piston and allied products pressure die casting and
cast iron parts is being undertaken. The production facilities are backed by well-equipped quality
assurance system,design and applied research facilities.

Atlas Engineering policy and operations are guided by the management approach of Atlas Group,
Organization development through self development.

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 CONTENT Page. No
Piston Machine
 Production Planing
 Production Control
 Machining Process
 Gstudo
 Monthly Order
 Order Cycle
 Production Planning and Production
Control
Purpose:
The purpose is to determine the planning and capacity planning of the plant.

Function:
 The basic function of this Piston Machine is project monitoring, capacity planning of
the plant, ordering of material, inspection of shortage.
 To make monthly rundown on the basis of discussion done in production meeting.
 To make production plan on the basis of order.
 They prepare plan on the basis of Consumer demand and availability of material.

Getsudo (ordering month) (N-2)

Ordering Packaging Production

N-2 cycle illustrate the production month that occurs two months after the order is being made.
It works in a way that if Atlas Eng (Piston Machine) has to produce in month of February so it
has to order in December, packing proceed in January and production will start in
February.

The above figure shows the detailed information of the ordering schedule.

D-18 is the first production day that is 18 days before months end
D-17 maximum capacity guide meeting is observed in which Atlas discuss the production
capacity, production days for the smooth flow of production

D-14 the GWSS that is the working sheet is circulated to different parts as mentioned. GWSS
is a working sheet in which Atlas placed order then this order runs into SAP which will be send
to all suppliers.On D-14 Atlas place 6 months Lots tentative varaint wise order.

D-14 is noted as half production day or No production day which is observed as to balance
production capacity

Monthly Order
Plotting bill of material that is the total material required to form complete Production
against production plan, monthly requirenment of direct consumable is obtained

Order Cycle

Figure 6: Order Cycle

 Order sheet has been made to know what material Atlas Engineering needed in what
quantity.
 PFI(Perfoma Invoice) is made by supplier to provide the complete knowledge
about the quantity he could supply
  PO is purchase order that is made in system to store all information that has been
mentioned in PFI.
 Finance department of Atlas issued LC to the bank which assures that payment is
going to be released when order is received.
 Talex is verification of bank which provide communication to supplier that Atlas
Engineering has made the payment
 Shipping invoice is now forwaded to importer to know about shipping details
 Inbound is made to inform the logistics that shipment is going to be arrived on certain date.
 calculation of duties has been made which then paid to receive the order
 After port process order received by the Atlas.

The process appears so smooth but it is so complex, it requires hundreds of skilled workers to
complete this process as this is manual process.
Flow Chart

Raw Material

Testing &
Storage

Casting

Rejection
Rejection Machining

Final
Inspection

Ware
House
 TECHNICAL ASPECTS
Automobile Piston - Introduction

In an Internal Combustion engine, piston converts the thermal energy of fuel into
mechanical energy. The main functions of the piston are

(a) To transmit the gas forces via connecting rod to the crank shaft.
(b) To seal in conjunction with the piston rings and combustion chamber against gas
leakage to the crankcase and to prevent the infiltration of oil from crankcase into the
combustion chamber.
(c) o dissipate absorbed combustion heat to the cylinder liner and cooling oil.

Operating Conditions

Pistons are subject to high mechanical and thermal loads.The mechanical loads on the
piston result from extreme pressure cycles with peak pressures upto 200 bar in
combustion chamber and huge forces of inertia caused by extremely high acceleration
during the reciprocating motion of piston. The thermal loads on the piston result from
combustion process with peak gas temperatures in the combustion chamber between
1800 to 2600 °C. For pistons, these challenges translate into maximum strength
requirements in the relevant temperature range combined with minimum weight.

Raw Material

Aluminum is used for manufacturing pistons, where as, little quantities of other elements such as
Silicon,Magnesium, and Iron also take part in piston manufacturing.AC8H is used for piston
because of its vaious reasons it gives good

 Machinability
 Good resistance to corrosion
 Low density
 High thermal conductivity
 Very good recycling characteristics

Proper control of the chemical composition, processing conditions and final heat treatment results
in a micro structure which ensures the required mechanical and thermal performance, in particular
the high thermal fatigue resistance.

Process of Manufacture

The aluminium alloy is formed into roughly shaped piston blanks either by casting or forging.
Thereafter, piston blanks are machined to final specification.But in Atlas Casting method is used.

Cast Pistons
They are most common due to the simpler and less expensive manufacturing
processes involved. The majority of pistons are produced by gravity die casting process.
 Testing And Storage

Atlas Engineering Ltd. has its own lab, equipped with numerous machines related to material
testing, such as, SpectroMAX, Brinnel & Rockwell hardness testing machines etc.

The ingots purchased from dealers are first checked for there composition. One ingot is taken out
from each bundle and sent to lab to check for its composition, SpectroMAX is used for this
purpose. Hardness is also tested in the lab, if the ingot is found to be in the permissible limit of the
composition and hardness, then it is stored in the stores and issued MIR (material issuing
requisite)

MACHINING

After Casting the casted parts are then moved to machining area, several machining operations
are performed here which gives pistons required shape.Six machining lines are there in machining
department.

Seat
Proof Turning
Machining Grooves

Lock Grooving Taper

Bore Drillin
g

Copy Turning Lug Removal Inspection

In machining area the manual lathes, automatic lathes, plc and drilling machines take part. The
process flow is a “U” which utilizes the workers in there best way. Each worker at the same time
works at two machines.

Processes

Proof Turning

 Three tools take part for the operation.

 Firstly two tools give rough finish to the piston skirt (two tools are used because of different
diameters are required).
 Then, the third tool descends to give piston head (not the head cavity) its final finish.
 Cutting fluid is also used here. The machining time is approx. 39 sec here.
 Than parts are moved to get there head cavity finished.

Seat Machining

 Seat of piston is making using Automatics Lathe

 Seat basically sets the reference for the preceding machining operations.
 The machining time is approx. 18 sec here.

Head Shape

 In this operation automatic lathe is used. Worker clamp the part w.r.t the seat made.
 Two tools take part in the operation. One tool removes the material from head giving it primary
rough finish and specifying its length,where as, the second tool makes the rough cavity in the head.
 Cutting fluid is used here to reduce the friction and heat and to carry the chips away.
 The machining time is approx. 25 sec here.

Taper Drill

 Automatic drilling machine is used here to drill the taper holes.

 Worker clamp the piston with respect to the seat made.
 These holes allow oil to get inside the piston.

Grooving
 Three Ring Grooves are Created by Lathe Machine.
.