SUMMER INTERNSHIP REPORT

ON
“MANUFACTURING PROCESSES OF EV MACHINE SHOP”
1ST AUGUST-31TH AUGUST,2023

K.I.E.T. GHAZIABAD
Department of Mechanical Engineering

SUBMITTED TO- SUBMITTED BY-

MR. IC PANDI Sr. MANAGER (E.V DEPT.) LUCKY
SHRIRAM PISTONS AND RINGS LTD., GHAZIABAD 3 rd year Student

1
 DECLARATION
I at this moment declare that the project work entitled MANUFACTURING
PROCESSES OF EV MACHINE SHOP is an authentic record of my own
work carried out at SHRIRAM PISTONS AND RINGS LTD., Ghaziabad as
a requirement of the Industrial Internship Project for the award of the degree of
B.TECH (MECHANICAL) UPTU, LUCKNOW, under the guidance of
Mr.Pankaj Sharma from the E.V. Machine shop department during August
2023.

Date: Name of Student:LUCKY

Certified that the above statement made by the student is correct to the best of
our knowledge and belief.

Industry coordinator

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 INDEX
S.NO. CONTENTS PAGE NO.

1. ACKNOWLEDGEMENT 4
2. INTRODUCTION 5
3. HEAT ENGINE 8
3.1. INTERNAL COMBUSTION ENGINE 8
3.1.1. CONSTRUCTION 8
3.1.2. WORKING PRINCIPLE 9
3.2. FOUR STROKE ENGINE 10
4. ENGINE VALVE MANUFACTURING PROCESS 13
4.1. WHAT IS ENGINE VALVE? 13
4.2. MANUFACTURING PROCESS 13
5. EV PROCESS OPERATING SEQUENCE 14
5.1. FRICTION WELDING 16
5.2. FORGING 17
5.3. UPSETTING 18
5.4. HEAT TREATMENT 19
5.5. SHOT BLAST 21
5.6. STRAIGHTENING 22
5.7. STEM CUTOFF 22
5.8. SEAT GROOVING 22
5.9. SEAT STELLITE 22
5.10. TIP DRILLING 23
5.11. TIP STELLITE 23
6. INSPECTION 24
6.1. ULTRASONIC TESTING 24
6.2. DYE PENETRATION TESTING 26
7. CENTRELESS GRINDING MACHINE 29
8. OUTER DIAMETER TURNING MACHINE 30
9. CRI 31
10. CONCLUSION 32

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 AKNOWLDGEMENT

Nothing concrete can be achieved without an optimal of inspiration and

perspiration.

I am very grateful to SHRIRAM PISTONS AND RINGS LIMITED,

GHAZIABAD for giving me the opportunity to undertake my summer internship
at their prestigious organization. It was very awesome learning experience for me
to have worked at this organization as this project involved many unique
manufacturing practices and challenges.
I want to convey my sincere thanks to Mr.Pankaj Kr. Jain(Plant Head) &Ms.
Monika Joshi (Manager-II).) who were instrumental in arranging the vocational
training at SPRL, Ghaziabad.
I would also like to give my heartfelt thanks to Mr.Pankaj Sharma (Dy.
Manager), Project Co-ordinator who guided and motivated me all through
summer training and imparted in-depth knowledge of the project. Also, I would
like to thank Mr.Tufail Khan, Mr. Ajay, and Mr. Dinesh Sharma who assisted
and guided me whenever I needed help. I would like to thank all the department
heads of SPRL for giving their precious time and valuable guidance during my
internship program.
Last but not least; I would like to thank all the employees of the organization for
being so helpful during my summer training.

LUCKY

4
 INTRODUCTION

ABOUT THE ORGANISATION:

Shriram Pistons & Rings Ltd. (SPRL) is one of the largest and most sophisticated
manufacturers of Precision Automobile components i.e. Pistons, Piston Rings, Piston Pin, and
Engine Valves in India. The products are sold under the brand name “USHA/SPR” in the
markets.
SPRL Manufacturing unit is located at Meerut Road in Ghaziabad (25 Km from Delhi). The
plant has been recognized as one of the most modern and sophisticated plants in North India in
the field of Automobiles.
SPR has an exceptional lineage of the Shriram group, one of India’s oldest and most reputed
industrial houses. SPR is recognized by almost all OEMs(Original Equipment Manufacturers)
in India and several in Europe and Asia, as a dependable partner for the supply of Euro III, IV
& V Pistons, Pins, Piston Rings, and Engine Valve.
The organization deploys the most modern manufacturing equipment and processes, using
state-of-the-art technology from four global leaders. SPR has evolved into a center of
manufacturing excellence, employing over 5000 motivated and multi-skilled employees. The
annual Turnover is US$ 200 million.
The company is the largest manufacturer and the largest exporter of pistons and rings from
India and the largest supplier of Engine valves to OEMs in India. Its products are marketed to
OEMs and aftermarket under the brands SPR and USHA, names that are synonymous with
quality and reliability.
Total customer satisfaction through quality management and continuous improvement has seen
SPR grow from strength to strength. And through our policy of customer first, we don’t just
occupy our customers’ mind space but their heart space too. Building long-term relationships
through excellent products, constant attention to their requirements, and anticipating their
needs even before they articulate them, have won us many accolades and consistent business.
Our products form an integral part of the portfolio of all leading OEMs in India and abroad,
including for Euro IV and V engines. Our Client list reads like who’s who of the automobile
industry and Ashok Leyland, Avtec, Bajaj, Cummins, Daimler, Ford, Greaves, Hero
MotoCorp, HMT, Honda, Kirloskar, Lombardini, Mahindra, Maruti, New Holland, Nissan,
Renault, Simpson, Suzuki, Swaraj Engines, Swaraj Mazda, TAFE, Tata Motors, Tata
Cummins, TVS, VE Commercial Vehicles, VM Motors (FIAT), Wabco, Yamaha and many
more.
Being customer-driven and bringing smiles, has its rewards. SPR is the first Piston, Ring, and
Engine valve manufacturer in India to receive the coveted TPM Excellence Award in 2004 and
the TPM Special Award in 2007 from JIPM, Japan. SPR has received awards from OEMs for

5
excellence in technology, Manufacturing Excellence, quality, Exports, and overall
performance. SPR is Ford Q1 Quality Certified and has Direct on Line (DOL) status with most
OEMs.
Export is at the core of SPR’s business strategy. Development and manufacturing of the latest
technology products for OEMs in Europe, the USA, etc. challenges the enterprise to home its
manufacturing process, technology, and quality to global standards. This acts as a catalyst to
transform the entire organization. Not surprisingly, SPR is the largest exporter of Pistons and
Rings from India to discerning customers, including Ford, Honda, Kia, and Renault, and
WABCO has the “Trading House” status from the government of India. SPR and USHA are
almost the best-recognised brand names in the aftermarket abroad.
We walk hand-in-hand with global technology leaders who share our commitment to product
quality, performance, and customer-centricity. We have technical collaboration with
Kolbenschmidt, Germany & Honda Foundry, Japan for Pistons, Riken Corporation, Japan for
Rings, and Fuji Oozx, Japan for Engine Valves.

I- RUN
I- MAINTAIN
I- CHECK

ORGANISATIONAL OBJECTIVE
1. Organisation that is sensitive and interactive to the needs of the customer.
2. Continuous upgrading of quality and process to meet the challenging needs of the
customer.
3. Optimization of return on investment by
➢ Continuous Improvement
➢ Technology Development
➢ Organisational and Personnel Development
➢ Cost reduction efforts
➢ Effective use of all resources
➢ Harmonious and safe working environment
4. Work with international norms for quality and management.
The company has successfully practiced the best work ethics and technology with the TPM &
Kaizen approach and harmony through teamwork.

ACHIEVEMENTS IN TERMS OF QUALITY

• SPR received the ISO-9001 certification from RWTUV, Germany in 1994. Technology
from the collaborators was supplemented with in-house efforts and by implementing
world-class practices.
• The company received the TPM Excellence Award in the year
• Best foundry awards from the Institute of Foundry Men in the year.

6
 • ISO/TS16949 achieved for SPR Unit-II Ghaziabad in the year 2009
• ISO/TS16949 achieved for SPR Unit V Pune in the year 2010.
• Received performance award from Honda Siel Power Products Ltd. in March 2012.
• Vendor performance from Suzuki motorcycle.

Features of SPR factory:

➢ The total area covered by the factory is 27 acres.
➢ The factory has manufacturing facilities for pistons, Rings, Pins, and Engine Valves.
➢ Classification of the premises:
P.T.E- Production Technology and Engineering
C.A.A- Commercial Administration and accounts
R&D- Research and Development
➢ The total strength of the company is 5918 nos. consisting of officers, staff, workers,
and contract labour.
➢ The turnover/Sales for the year 2014-2015 is Rs. 1280.6Cr
➢ The company is exporting to more than 35 countries.
➢ Export sales are Rs. 237cr the year 2013-2014.
➢ Over 10% of the production is exported to sophisticated markets such as Europe, the
UK, Egypt, the USA, Latin America, etc.
➢ SPR has been investing 30% of its retained earnings in quality gradation and
modernization every year.

Engine
Valve PLAN

Piston
Piston SPRL Pin
ACT QUALITY DO

Piston
CHECK
Rings

“A SUCCESSFUL TEAM IS A GROUP OF MANY HANDS BUT OF ONE

MIND”

7
 HEAT ENGINE

A heat engine is a machine, which converts heat energy into mechanical energy. The
combustion of fuel such as coal, petrol and diesel generates heat. This heat is supplied to a
working substance at high temperature. By the expansion of this substance in suitable
machines, heat energy is converted into useful work. Heat engines can be further divided into
two types:
(i) External combustion and
(ii) Internal combustion.
In a steam engine the combustion of fuel takes place outside the engine and the steam thus
formed is used to run the engine. Thus, it is known as external combustion engine.
In the case of internal combustion engine, the combustion of fuel takes place inside the engine
cylinder itself.

INTERNAL COMBUSTION ENGINES

An internal combustion engine (ICE) is a heat engine where the combustion of a fuel occurs
with an oxidizer (usually air) in a combustion chamber that is an integral part of the working
fluid flow circuit. In an internal combustion engine the expansion of the high-temperature and
high-pressure gases produced by combustion apply direct force to some component of the
engine. The force is applied typically to pistons,turbine blades, or a nozzle. This force moves
the component over a distance, transforming chemical energy into useful mechanical energy.
The first commercially successful internal combustion engine was created by Étienne
Lenoir around 1859and the first modern internal combustion engine was created in 1864
by Siegfried Marcus.

CONSTRUCTION OF AN IC ENGINE

I.C. engine converts the reciprocating motion of piston into rotary motion of the crankshaft by
means of a connecting rod. The piston which reciprocating in the cylinder is very close fit in
the cylinder. Rings are inserted in the circumferential grooves of the piston to prevent leakage
of gases from sides of the piston. Usually, a cylinder is bored in a cylinder block and a gasket,
made of copper sheet or asbestos is inserted between the cylinder and the cylinder head to avoid

8
ant leakage. The combustion space is provided at the top of the cylinder head where combustion
takes place. The connecting rod connects the piston and the crankshaft. The end of the
connecting rod connecting the piston is called the small end. A pin called a gudgeon pin or
wrist pin is provided for connecting the piston and the connecting rod at the small end. The
other end of the connecting rod connecting the crankshaft is called the big end. When the piston
is moved up and down, the motion is transmitted to the crankshaft by the connecting rod, and
the crank shaft makes a rotary motion. The crankshaft rotates in main bearings which are fitted
in the crankcase. A flywheel is provided at one end of the crankshaft for smoothing the uneven
torque produced by the engine. There is an oil sump at the bottom of the engine which contains
lubricating oil for lubricating different parts of the engine.

WORKING PRINCIPLE

A mixture of fuel with the correct amount of air is exploded in an engine cylinder which is
closed at one end. As a result of this explosion, heat is released and this heat causes the pressure
of the burning gases to increase. This pressure forces a close-fitting piston to move down the
cylinder. The movement of the piston is transmitted to a crankshaft by a connecting rod so that
the crankshaft rotates and turns a flywheel connected to it. Power is taken from the rotating
crankshaft to do mechanical work. To obtain continuous rotation of the crankshaft the
explosion has to be repeated continuously.

Before the explosion takes place, the used gases are expelled from the cylinder, fresh charge
of fuel and air is admitted into the cylinder and the piston is moved back to its starting position.
The sequence of events taking place in an engine is called the working cycle of the engine. The
sequence of events taking place inside the engine are as follows:

1. Admission of air or air-fuel mixture inside the engine cylinder (suction)

2. Compression of the air or air-fuel mixture inside the engine (compression)

3. Injection of fuel in compressed air for ignition of the fuel or ignition of air-fuel mixture byan
electric spark using a spark plug to produce thermal power inside the cylinder (power )

4. Removal of all the burnt gases from the cylinder to receive fresh charge (exhaust)

Note: Charge means admitting fresh air into the cylinder in the case of compression ignition
engines (diesel engines) or admitting a mixture of air and fuel into to thecylinder in the case of
spark ignition engines.

Typically an ICE is fed with fossil fuels like natural gas or petroleum products such
as gasoline, diesel fuel , or fuel oil. There's a growing usage of renewable

9
fuels like biodiesel for compression ignition engines and bioethanol for spark ignition engines.
Hydrogen is sometimes used and can be made from either fossil fuels or renewable energy.

FOUR-STROKE ENGINE

In four-stroke cycle engines, the four events namely suction, compression, power, and exhaust
take place inside the engine cylinder. The four events are completed in four strokes of the piston
(two revolutions of the crankshaft). This engine has got valves for controlling the inlet of charge
and outlet of exhaust gases. The opening and closing of the valve are controlled by cams, fitted
on the camshaft. The camshaft is driven by a crankshaft with the help of suitable gears or
chains. The camshaft runs at half the speed of the crankshaft. The events taking place in the
I.C. engine are as follows:
1. Suction stroke 2. Compression stroke
3. Power stroke 4. Exhaust stroke

10
 SEQUENCE OF STROKES IN A FOUR-STROKE CYCLE ENGINE
The top dead centre (TDC) of a piston is the position where it is nearest to the valves; bottom
dead centre (BDC) is the opposite position where it is furthest from them. A stroke is the
movement of a piston from TDC to BDC or vice versa together with the associated process.
While an engine is in operation the crankshaft rotates continuously at a nearly constant speed.
In a 4-stroke ICE each piston experiments 2 strokes per crankshaft revolution in the following
order. Starting the description at TDC, these are:-

SUCTION

EXHAUST COMPRESSIO
STROKES
N

POWER

1. Intake or Suction Stroke: During suction stroke inlet valve opens and the piston
moves downward. Only air or a mixture of air and fuel are drawn inside the cylinder. The
exhaust valve remains in closed position during this stroke. The pressure in the engine
cylinder is less thanatmospheric pressure during this stroke.

11
2. Compression Stroke: During this stroke the piston moves upward. Both valves are in
closed position. The charge taken in the cylinder is compressed by the upward movement
of piston. If only air is compressed, as in case of diesel engine, diesel is injected at the end
of the compression stroke and ignition of fuel takes place due to high pressure and
temperature of the compressed air. If a mixture of air and fuel is compressed in the cylinder,
as in case of petrol engine, the mixture is ignited by a spark plug.
3. Power or working stroke: After ignition of fuel, tremendous amount of heat is
generated, causing very high pressure in the cylinder which pushes the piston downward
(Fig.1b). The downward movement of the piston at this instant is called power stroke. The
connecting rod transmits the power from piston to the crank shaft and crank shaft rotates.
Mechanical work can be taped at the rotating crank shaft. Both valves remain closed during
power stroke.

4. Exhaust Stroke: During this stroke piston moves upward. Exhaust valve opens and
exhaust gases go out through exhaust valves opening. All the burnt gases go out of the
engine and the cylinder becomes ready to receive the fresh charge. During this stroke inlet
valve remains closed.

Thus it is found that out of four strokes, there is only one power stroke and threeidle strokes in
four stroke cycle engine. The power stroke supplies necessarymomentum for useful work.

Valve timing diagram

12
ENGINE VALVE MANUFACTURING
PROCESS

13
What is an engine valve?
Engine valves are essential parts for engine functioning. They are located in the cylinder head
and can be classified into intake valves and exhaust valves. The intake valves bring in air/fuel
into chamber for combustion and the exhaust valves let exhaust out after burning. The open
and close of valves are decided by the cylinder piston positions.

MANUFACTURING PROCESS

RAW
MATERIALS

MACHINE
TOOLS AND
LABOUR

DESIRED
PRODUCTS

Thus, manufacturing process is defined as the conversion of raw materials to finished products
with the application of machine tools and labour.

EV PROCESS OPERATION SEQUENCE (POS)

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 CUT BARS

FRICTION WELDING

FORGING

UPSETTING/EXTRUSION

HEAT TREATMENT

SHOT BLASTING

STRAIGHTENING

STEM CUT OFF

SEAT GROOVING

SEAT STELLITE

TIP DRILLING

15
 TIP STELLITE

END GRINDING

NON-DESTRUCTIVE TESTING

DELIVERY TO M/C SHOP

CENTRELESS GRINDING MACHINE

OD TURNING MACHINE

COPY TURNING MACHINE

GROOVING

INDUCTION HARDENING

FINISH CENTERLESS GRINDING

16
 CHROME PLATING

SEAT GRINDING

END LAPPING

CUSTOMER RELIABLE AND INSPECTION (CRI)

PACKING AND TRANSPORTATION

17
FRICTION WELDING
PRINCIPLE:-
Friction welding (FRW) is a solid-state welding process that generates heat through
mechanical friction between workpieces in relative motion to one another, with the addition of
a lateral force called "upset" to plastically displace and fuse the materials. Technically, because
no melt occurs, friction welding is not actually a welding process in the traditional sense, but
a forging technique.

PROCESS OF SEQUENCE (POS)

CUTTED BARS (2-DIFFERENT MATERIALS) {INPUT}

HOLDED IN JAWS (ROTATING AND STATIONARY JAW)

ROTATING JAW ROTATED (WITH RESPECT TO STATIC JAW)

LATERAL FORCE APPLIED TO BARS

FRICTION GENERATED

HEAT GENERATED

DISPLACEMENT OF ATOMS TOWARDS EACH OTHER

FUSING OF BARS TO EACH OTHER (OUTPUT)

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FORGING
Forging is a manufacturing process involving the shaping of metal using localized compressive
forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is
often classified according to the temperature at which it is performed: cold forging (a type of
cold working), warm forging, or hot forging (a type of hot working). For the latter two, the
metal is heated, usually in a forge. Forged parts can range in weight from less than a kilogram
to hundreds of metric tons. Forging has been done by smiths for millennia; the traditional
products were kitchenware, hardware, hand tools, edged weapons, and jewellery. Since the
Industrial Revolution, forged parts are widely used in mechanisms and machines wherever a
component requires high strength such forgings usually require further processing (such as
machining) to achieve a finished part. Today, forging is a major worldwide industry.

PRINCIPLE
The material is being heated below melting temperature and thus force is applied on it as for
the desired shape needed.Thus also known as Metal Forming Process.
PROCESS OF SEQUENCE
UPSETTED BAR IS PUT OVER DIE (INPUT)

HIGH IMPACT FORCE OVER BAR

F
R
FRICTION GENERATED IB/W BAR AND PUNCH
C
T
I
AS HEAT IS PRESENT IN THE BAR
O
N
BAR GETS THE DESIREDG SHAPE (OUTPUT)
E
N
E
19R
A
T
E
UPSETTING
Upset forging increases the diameter of the workpiece by compressing its length. Friction
forces at the die-work interface oppose the spreading of the material near the surfaces, while
the material in the centre can expand more easily.

PROCESS OF SEQUENCE (POS)

FRICTION WELDED BAR HOLDED B/W DIES (COLDER& HOTTER DIES)(INPUT)

COLDER DIE MOVE TOWARDS HOTTER DIE WITH A DESIRED VELOCITY (AS
UPSET NEEDED)

FRICTION B/W ATOMS OF BAR

HEAT GENERATION

MATERIAL SPREADING TOWARDS HOTTER REGION

INCREASING DIAMETER AND DECREASING LENGTH

DESIRED UPSET (OUTPUT)

20
HEAT TREATEMENT
Heat treating is a group of industrial and metalworking processes used to alter the physical,
properties of a material. The most common application is metallurgical. Heat treatments are
also used in the manufacture of many other materials, such as glass. Heat treatment involves
the use of heating or chilling, normally to extreme temperatures, to achieve a desired result
such as hardening or softening of a material. Heat treatment techniques include annealing, case
hardening, precipitation strengthening, tempering and quenching. It is noteworthy that while
the term heat treatment applies only to processes where the heating and cooling are done for
the specific purpose of altering properties intentionally, heating and cooling often occur
incidentally during other manufacturing processes such as hot forming or welding.

Effects of time and temperature

Proper heat treating requires precise control over temperature, time held at a certain
temperature and cooling rate.
With the exception of stress-relieving, tempering, and aging, most heat treatments begin by
heating an alloy beyond the upper transformation (A3) temperature. This temperature is referred
to as an "arrest" because, at the A3 temperature nothing happens. Therefore, the alloy must be
heated above the temperature for a transformation to occur. The alloy will usually be held at
this temperature long enough for the heat to completely penetrate the alloy, thereby bringing it
into a complete solid solution.
Because a smaller grain size usually enhances mechanical properties, such as toughness, shear
strength and tensile strength, these metals are often heated to a temperature that is just above
the upper critical temperature, in order to prevent the grains of solution from growing too large.
For instance, when steel is heated above the upper critical temperature, small grains of austenite

21
form. These grow larger as temperature is increased. When cooled very quickly, during a
martensite transformation, the austenite grain-size directly affects the martensitic grain-size.
Larger grains have large grain-boundaries, which serve as weak spots in the structure. The
grain size is usually controlled to reduce the probability of breakage.

The diffusion transformation is very time-dependent. Cooling a metal will usually suppress the
precipitation to a much lower temperature. Austenite, for example, usually only exists above
the upper critical temperature. However, if the austenite is cooled quickly enough, the
transformation may be suppressed for hundreds of degrees below the lower critical
temperature. Such austenite is highly unstable and, if given enough time, will precipitate into
various microstructures of ferrite and cementite. The cooling rate can be used to control the
rate of grain growth or can even be used to produce partially martensitic microstructures .
However , the martensite transformation is time-independent. If the alloy is cooled to the
martensite transformation (Ms) temperature before other microstructures can fully form, the
transformation will usually occur at just under the speed of sound.

When austenite is cooled slow enough that a martensite transformation does not occur, the
austenite grain size will have an effect on the rate of nucleation, but it is generally temperature
and the rate of cooling that controls the grain size and microstructure. When austenite is cooled
extremely slow it will form large ferrite crystals filled with spherical inclusions of cementite.
This microstructure is referred to as "sphereoidite." If cooled a little faster, then coarse pearlite
will form. Even faster, and fine pearlite will form. If cooled even faster, bainite will form.
Similarly, these microstructures will also form if cooled to a specific temperature and then held
there for a certain time.

Most non-ferrous alloys are also heated in order to form a solution. Most often, these are then
cooled very quickly to produce a martensite transformation, putting the solution into
a supersaturated state. The alloy, being in a much softer state, may then be cold worked.
This cold working increases the strength and hardness of the alloy, and the defects caused
by plastic deformation tend to speed up precipitation, increasing the hardness beyond what is
normal for the alloy. Even if not cold worked, the solutes in these alloys will usually precipitate,
although the process may take much longer. Sometimes these metals are then heated to a
temperature that is below the lower critical (A1) temperature, preventing recrystallization, in
order to speed-up the precipitation.

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 HEAT TREATEMENT

ANNEALING TEMPERING

STRESS RELIEVING QUENCHING

INDUCTION HARDENING

PROCESS OF SEQUENCE
FORGED BARS (INPUT)

BARS IN HEATING FURNACE (APPROX. 2HRS)

QUENCHING MEDIUM (OIL/WATER/SALT/AIR)

HEAT TREATED BARS (OUTPUT)

SHOT BLASTING
Shotblasting is a method used to clean, strengthen (peen) or polish metal. Shot blasting is
used in almost every industry that uses metal, including aerospace, automotive, construction,
foundry, shipbuilding, rail, and many others.
PROCESS OF SEQUENCE
HEAT TREATED BARS

KEPT IN ROTATING BLASTER MACHINE

METAL POWDERS POURED IN M/C

BARS AND POWER BOTH COLLIDE TO EACH OTHER

SHOT BLASTED BARS (OUTPUT)

23
STRAIGHTENING
Straightening is the metal forming process in which shot blasted bars are straightened in
between the rollers using localised compressive forces.

STEM CUT OFF

During this operation valve stem is cut off from turning machine as the desired dimensions
needed.

SEAT GROOVING

PROCESS OF SEQUENCE
VALVE HOLDED IN CHUCK

TOOL SET TO AN ANGLE

VALVE GROOVED

SEAT STELLITE
Seat stellite is used to harden the face of the valve.
Stellite alloy is a range of cobalt-chromium alloys designed for wear resistance. It may also
contain tungsten or molybdenum and a small but important amount of carbon. It is
atrademarked name of the Kennametal Stellite Company and was invented by Elwood
Haynesin the early 1900s as a substitute for cutlery that stained (or that had to be constantly
cleaned).
There are a large number of Stellite alloys composed of various amounts
of cobalt, nickel, iron, aluminium, boron, carbon, chromium, manganese, molybdenum, phos
phosphorus,sulphur, silicon, and titanium, in various proportions, most alloys containing four
to six of these elements.

Stellite is a family of completely non-magnetic and corrosion-resistant cobalt alloys of various

compositions that have been optimised for different uses. Information is available from the
manufacturer, Kennametal Stellite, outlining the composition of a number of Stellite alloys and
their intended applications. The alloy currently most suited for cutting tools, for example, is
Stellite 100, because this alloy is quite hard, maintains a good cutting edge even at high
temperature, and resists hardening and annealing. Other alloys are formulated to maximize

24
combinations of wear resistant, corrosion resistance, or ability to withstand extreme
temperatures.
Stellite alloys display outstanding hardness and toughness, and are also usually very resistant
to corrosion. Stellite alloys are so hard that they are very difficult to machine, and anything
made from them is, as a result, very expensive. Typically, a Stellite part is precisely cast so that
only minimal machining is necessary. Stellite is more often machined by grinding, rather than
by cutting. The alloys also tend to have extremely high melting points due to the cobalt and
chromium content.
PROCESS OF SEQUENCE
SEAT GROOVED VALVE (INPUT)

DEPOSITION OF STELLITE (PLASMA POWDER WEDLING M/C)

SEAT STELLITE VALVE (OUTPUT)

TIP DRILLING
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-section
in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is pressed
against the workpiece and rotated at rates from hundreds to thousands of revolutions per
minute.

TIP STELLITE

The tip of the valve is first drilled to fill the stellite in it as to make the tip hardened. The stellite
used is of alloy.

INSPECTION
ULTRASONIC TESTING

Ultrasonic testing (UT) is a family of non -destructive techniques based on the propagation of
ultrasonic waves in the object or material tested. In most common UT applications, very short
ultrasonic pulse-waves with centre frequencies ranging from 0.1-15 MHz, and occasionally up
to 50 MHz, are transmitted into materials to detect internal flaws or to characterize materials.
A common example is ultrasonic measurement, which tests the thickness of the test object, for
example, to monitor pipework corrosion.

25
Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be
used on concrete, wood and composites, albeit with less resolution. It is used in many industries
including steel and aluminium construction, metallurgy,
manufacturing, aerospace, automotive and other transportation sectors.

Principle
The general principle of this device consists of sending high frequency vibrations into the part
to be inspected, and the determination of the time intervals of arrival of the direct and reflected
vibrations at one or more stations on the surface of the part.
For detecting the presence of inhomogeneities of density or elasticity in materials. For instance
if a casting has a hole or a crack within it, the device allows the presence of the flaw to be
detected and its position located, even though the flaw lies entirely within the casting and no
portion of it extends out to the surface.

PROCESS OF SEQUENCE
END GRINDED VALVE (INPUT)

ULTRASONIC TRANSDUSER

26
 CONNECTED TO DIAGONISTIC M/C

PASSED OVER OBJECT TO BE INSPECTED

TRANSDUCER IS TYPICALLY SEPERATED FROM THE TEST OBJECT BY A

COUPLANT (SUCH AS OIL/WATER AS IN IMMERSION TESTING)

DISPLAY RESULT IN FORM OF SIGNAL WITH AMPLITUDE REPRESENTING THE

INTENSITY OF REFLECTION AND DISTANCE

IMPERFECTION REDUCE THE AMOUNT OF SOUND TRANSFERRED

SHOWING THE DEFECT IF PRESENT

VALVE INSPECTED

DYE PENETRANTION TESTING

Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or penetrant
testing (PT), is a widely applied and low-cost inspection method used to locate surface-
breaking defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may
be applied to all non-ferrous materials and ferrous materials, although for ferrous
components magnetic-particle inspection is often used instead for its subsurface detection
capability. LPI is used to detect casting, forging and welding surface defects such as hairline
cracks, surface porosity, leaks in new products, and fatigue cracks on in-service components.

The oil and whiting method used in the railroad industry in the early 1900s was the first
recognized use of the principles of penetrants to detect cracks. The oil and whiting method used
an oil solvent for cleaning followed by the application of a whiting or chalk coating, which
absorbed oil from the cracks revealing their locations. Soon a dye was added to the liquid. By

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the 1940s, fluorescent or visible dye was added to the oil used to penetrate test
objects.Experience showed that temperature and soak time were important. This started the
practice of written instructions to provide standard, uniform results. The use of written
procedures has evolved, giving the ability for design engineers and manufacturers to get the
high standard results from any properly trained and certified liquid penetrant testing technician.

PRINCIPLE
DPI is based upon capillary action, wherelowsurface tension fluid penetrates into clean and dry
surface-breaking discontinuities. Penetrant may be applied to the test component by dipping,
spraying, or brushing. After adequate penetration time has been allowed, the excess penetrant
is removed and a developer is applied. The developer helps to draw penetrant out of the flaw
so that an invisible indication becomes visible to the inspector. Inspection is performed under
ultraviolet or white light, depending on the type of dye used - fluorescent or non-fluorescent
(visible).
PROCESS OF SEQUENCE
PRE-CLEANING

APPLICATION OF PENETRANTE

EXCESS PENETRANTE REMOVAL

APPLICATION OF DEVELOPER

INSPECTION
Pre-cleaning

The test surface is cleaned to remove any dirt, paint, oil, grease or any loose scale that could
either keep penetrant out of a defect, or cause irrelevant or false indications. Cleaning methods
may include solvents, alkaline cleaning steps, vapour decreasing, or media blasting. The end
goal of this step is a clean surface where any defects present are open to the surface, dry, and
free of contamination. Note that if media blasting is used, it may "work over" small
discontinuities in the part, and an etching bath is recommended as a post-blasting treatment.

Application of Penetrant

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The penetrant is then applied to the surface of the item being tested. The penetrant is allowed
"dwell time" to soak into any flaws (generally 5 to 30 minutes). The dwell time mainly depends
upon the penetrant being used, material being tested and the size of flaws sought. As expected,
smaller flaws require a longer penetration time. Due to their incompatible nature one must be
careful not to apply solvent-based penetrant to a surface which is to be inspected with a water-
washable penetrant.

Excess Penetrant Removal

The excess penetrant is then removed from the surface. The removal method is controlled by
the type of penetrant used. Water-washable, solvent-removable, lipophilic post-emulsifiable,
or hydrophilic post-emulsifiable are the common choices. Emulsifiers represent the highest
sensitivity level, and chemically interact with the oily penetrant to make it removable with a
water spray. When using solvent remover and lint-free cloth it is important to not spray the
solvent on the test surface directly, because this can remove the penetrant from the flaws. If
excess penetrant is not properly removed, once the developer is applied, it may leave a
background in the developed area that can mask indications or defects. In addition, this may
also produce false indications severely hindering your ability to do a proper inspection..Also
the removal of excessive penetrant is done towards one direction either vertically or
horizontally as the case may be.

Application of Developer
After excess penetrant has been removed a white developer is applied to the sample. Several
developer types are available, including: non-aqueous wet developer, dry powder, water
suspendable, and water soluble. Choice of developer is governed by penetrant compatibility
(one can't use water-soluble or suspendable developer with water-washable penetrant), and by
inspection conditions. When using non-aqueous wet developer (NAWD) or dry powder, the
sample must be dried prior to application, while soluble and suspendable developers are applied
with the part still wet from the previous step. NAWD is commercially available in aerosol spray
cans, and may employ acetone, isopropylealchohol, or a propellant that is a combination of the
two. Developer should form a semi-transparent, even coating on the surface.
The developer draws penetrant from defects out onto the surface to form a visible indication,
commonly known as bleed-out. Any areas that bleed-out can indicate the location, orientation
and possible types of defects on the surface. Interpreting the results and characterizing defects
from the indications found may require some training and/or experience [the indication size is
not the actual size of the defect.

Inspection

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The inspector will use visible light with adequate intensity (100 foot-candles or 1100 lux is
typical) for visible dye penetrant. Ultraviolet (UV-A) radiation of adequate intensity (1,000
micro-watts per centimeter squared is common), along with low ambient light levels (less than
2 foot-candles) for fluorescent penetrant examinations. Inspection of the test surface should
take place after 10 to 30 minute development time, depends of product kind. This time delay
allows the blotting action to occur. The inspector may observe the sample for indication
formation when using visible dye. It is also good practice to observe indications as they form
because the characteristics of the bleed out are a significant part of interpretation
characterization of flaws.

Post Cleaning
The test surface is often cleaned after inspection and recording of defects, especially if post-
inspection coating processes are scheduled.

Visual inspection
Visual inspection is a common method of quality control, data acquisition, and data analysis.
Visual Inspection, used in maintenance of facilities, mean inspection of equipment and
structures using either or all of raw human senses such as vision, hearing, touch and smell
and/or any non-specialized inspection equipment. Inspections requiring Ultrasonic, X-Ray
equipment, Infra-red, etc. are not typically regarded as Visual Inspection as these Inspection
methodologies require specialized equipment, training and certification.

CENTRELESS GRINDING MACHINE

Principle

Centerless grinding is a machining process that uses abrasive cutting to remove material from
a workpiece. Centerless grinding differs from centered grinding operations in that
no spindle or fixture is used to locate and secure the work piece. The work piece is secured
between two rotary grinding wheels, and the speed of their rotation relative to each other
determines the rate at which material is removed from the work piece.
Centerless grinding is typically used in preference to other grinding processes for operations
where many parts must be processed in a short time.

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 Process of sequence
INSPECTED VALVE (INPUT)

PLACED B/W STATIC AND REGULATING WHEELS

COMPRESSIVE FORCES FROM WHEELS

FRICTION GENERATION

HEAT GENERATED IN VALVE

MACHINING PERFORMED ON STEM (OUTPUT)

OUTER DIAMETER TURNING MACHINE

Turning is a form of machining, a material removal process, which is used to create rotational
parts by cutting away unwanted material. The turning process requires a turning machine or
lathe,workpiece, fixture, and cutting tool. The workpiece is a piece of pre-shaped material that
is secured to the fixture, which itself is attached to the turning machine, and allowed to rotate
at high speeds. The cutter is typically a single-point cutting tool that is also secured in the
machine, although some operations make use of multi-point tools. The cutting tool feeds into
the rotating workpiece and cuts away material in the form of small chips to create the desired
shape.

Turning is used to produce rotational, typically axi-symmetric, parts that have many features,
such as holes, grooves, threads, tapers, various diameter steps, and even contoured surfaces.

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Parts that are fabricated completely through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom designed shafts and fasteners.
Turning is also commonly used as a secondary process to add or refine features on parts that
were manufactured using a different process. Due to the high tolerances and surface finishes
that turning can offer, it is ideal for adding precision rotational features to a part whose basic
shape has already been formed.

PROCESS OF SEQUENCE
GRINDED VALVES (INPUT)

HOLDED IN CHUCK

FACE OUTER DIAMETER TURNING (OUTPUT)

GROOVING
In grooving process, grooves are made on the stem of the engine valve with the help of
multiuse grinder machine where the valve is held in the spindle and the groove is generated.

COTTER GROOVE

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INDUCTION HARDENING
Induction hardening is a form of heat treatment in which a metal part is heated by induction
heating and then quenched. The quenched metal undergoes a martensitic transformation,
increasing the hardness and brittleness of the part. Induction hardening is done in Stress
Relieving Furnace valve is heated to a temperature of 180⁰C for 75 min.

INDUCTION HARDENING

FINISH CENTRELESS GRINDING

In this process, outer diameter grinding and finish operation is done on the centreless
grinding machine. Centerless grinding, if set up properly, will achieve roundness, surface
finish and dimensionnal tolerances that are among the best available in metal working.

CHROME PLATING
Chrome plating (less commonly chromium plating), is a technique of electroplating a thin
layer of chromium onto a metal or plastic object. The chromed layer can provide corrosion
resistance, ease cleaning procedures, or increase surface hardness.

CHROME PLATING
PROCESS OF SEQUENCE (POS)
DEGREASING

WATER RINSING

CLAMPING IN FIXTURES

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 ETCHING AND LOADING

PLATING

UNLOADING

WATER RINSING

UNCLAMPING

NEUTRALISING

OILING

TUFFRIDING
This process is done to increase the surface hardness of the valve and the chemical used is
REG1 and TF1.
PROCESS OF OPERATION
FIXTURE LOADING

DEGREASING

WATER RINSING

PREHEATING

TUFFRIDING

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 AIR QUENCHING

HOT WATER QUENCHING

COLD WATER QUENCHING

UNLOADING

VIBROFINISH

TRAY FILLING AND INSPECTION

SEAT GRINDING
The coming up process id Seat Grinding. The grinding process need to meet the accuracy
required since seat angle is critical surface to ensure complete sealing of the combustion
chamber with valve seat insert.

Seat Grinding

END LAPPING
Lapping is a machining process, in which two surfaces are rubbed together with an abrasive
between them, by hand movement or using a machine . This is the process of reducing the
length of the stem after grooving.

CRI (CUSTOMER RELIABLE AND INSPECTION)

The last step is performed in CRI where leak testing, valve multi testing, and visual inspection
are being performed.

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LEAK TEST: Leak testing is a process used to detect manufacturing defects which helps
verify the integrity of products and improve consumer safety. For example, the automotive
industry consistently uses leak testing to verify that assembly operations were completed
properly and subcomponents are leak free. Leak test works on the principle that the pressure
drop should not be more than 0.02MPa in 2 sec.

PACKNING AND TRANSPORTATION

After CRI valves are just being packed for different customers and transported as per locations.

FOUR WAYS TO GO AHEAD

OEE- OVERALL EQUIPMENT EFFECTIVENESS
REJECTION- <1%

PEOPLE CONNECTIVITY

INNOVATION

TRAINING AND
FLEXIBILITY
MOTIVATION

COMMON GOALS
CHALLENGES AND
RECOGNISATION

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 CONCLUSION

It was a wonderful learning experience at SHRIRAM PISTONS AND RINGS

LIMITED for One and Half months in Ghaziabad. I gained a lot of insight
regarding almost many aspects of manufacturing process. I was given exposure
in almost all the departments in the organisation. The friendly welcome from all
the employees is appreciating, sharing their experience and giving their peace of
wisdom which they have gained in long journey of work. I hope this experience
will surely help me in my future and also in shaping my career.

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