Taibah University

Collage of Engineering
Mechanical Engineering Department
Project of Manufacturing process
Section MA

Advisor:
Figure 1-1 [Dr.SALMAN NIZZAR]
Design Team
Presentation of Piston Alawy Yousef Foly 3695932
Ali Melad Lutfe 3695933
Firas Nasser AL-johani 3700678
Haitham AL-khatib 3704973
Hani Ahmad AL-Basheer 3702440
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 Introduction

Piston is Solid cylinder or disk that fits exactly into a hollow cylinder and moves back
,and forth under the pressure of a fluid (typically a hot gas formed by combustion
.as in many engines), or moves or compresses a fluid, as in a pump or compressor

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 :History

The development of the piston engine marked the beginning of the industrialization period in
Europe, setting the stage for the mass production of steam engines, automobiles and airplanes.
Piston engines provided lots of power without weighing down the machine, allowing planes,
.trains and cars to accelerate and reach speeds that no other mode of transport had ever achieved

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 Function

 
:Function of the product -1
.To transmit the force as a result of combustion to the crankshaft
.To make the cylinder close so that the high-pressure gases in the combustion chamber to prevent any leakage from happening
.Control the movement of connecting rod
.generates the variable volume in the combustion chamber

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 Function
The Crown is the top surface of the piston which is subjected
.to tremendous forces and heat during all engine operation
The Ring Lands are the distance between the piston crown and
.the ring groove
Ring Groove is a recessed area located around the perimeter of
.the piston that is used to retain the piston ring
piston Skirt is the portion which is closest to the crank shaft
.that helps align the piston as it moves in the cylinder bore
Wrist Pin Boss is a bore that connects the small end of the Figure 1-2
.connecting rod and the piston by a wrist pin

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 :Mechanism of the component

The mechanism consist of piston, connecting rod, crankshaft. There is a motor connected to the
crankshaft it allows to it to make pure rotation. therefore, connecting rod will make complex
.motion which is translation and piston will make pure translation

Figure 1-3

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 Piston Types

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 Offset piston pin

The piston pin is offset towards the major thrust Side of the piston to reduce Piston wear, and
.piston noise
he majors thrust side is the Side that is loaded during the power event The minor thrust side is
the reloaded during the Compression event

Figure 1-4

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 CAM ground piston

.Most pistons are CAM ground, this means they are not perfectly round
The diameter is larger on the non-thrust sides, because they tend to expand
.more as the temperature of the piston increases

Figure 1-5

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 Oil cooled piston

.A cavity is provided underneath the piston crown

To reduce the piston temperature at the top ring to prevent carbon formation in the groove and to
.achieve enough oil film thickness on the ring periphery
.This type of piston is provided in the medium and heavy speed diesel engines

Figure 1-6

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 Taper piston

.The crown side being smaller in diameter then the skirt end
As higher temperature occurs towards the crown, that side expands more than the skirt, due to
.which the piston diameter becomes uniform under running conditions

Figure 1-7

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 Cost of pistons

: Average value of a piston in different usages

.For diesel engine  75- 86
.For high quality engine 112.5– 187.5
.For marine engine 300-356.3
.Mitsubishi engine spare 18.75 - 56.25
.Engine Piston for Caterpillar 93.75-131.25
.For ford engine 3.5L ..225 – 33All prices in SAUDI RIYAL

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 Piston materials

Cast iron pistons •

Aluminum - cast pistons •
.Hypoeutectic •
Aluminum - Forged piston •

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 Cast iron pistons
.High strength •
.Good wearing characteristics •
.Low thermal expansions. • Heavier then aluminum pistons •
.Low thermal conductivity •

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 Aluminum - cast pistons

.Si-9to 12%, Ni- 1%. Cu- 1%,Mg- 1%etc •

.Lighter weight.• Economical •
.General usage •
.Brittle •

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 Hypoeutectic
.Si- 18to24%, Ni- I %. Cu- I %,Mg-1 %elc •
.Cast Aluminum with a high Silicon Content •
Lighter weight then normal cast,25% •
.Aluminum piston •
.High performance •
.Less Brittle •
.More Scuffing resistance •
.Expensive then cast pistons •

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 Aluminum - Forged piston

.Si-9to 12%, Ni- I %. Cu- I %.Mg- 1%etc •

.Lighter in weight than normal cast piston •
.Stronger then normal cast piston •
.Due to less porosity they can conduct heat more rapidly •
Approximately runs 20% cooler then cast piston •

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 Piston Manufacturing

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• Piston material and design contribute to the overall durability and
performance of an engine.

• Most pistons are made from cast aluminum alloy.

• Cast aluminum alloy is lightweight and has good structural integrity and low
manufacturing costs. The light weight of aluminum reduces the overall mass and force
necessary to initiate and maintain acceleration of the piston.

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 Piston Manufacturing Process

• 1- The pistons are usually manufactured by two methods

1- CASTING (an object made by pouring molten metal or other material into a mold
2- FORGING (Forging is the operation where the metal is heated and then a force is applied to manipulates the metals in
such a way that the required final shape is obtained

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 MANUFACTURING BY CASTING

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 Figure 1-9
Figure 1-8

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 4) 5 axis VMC machining
• In this machine the oil slots and pin bore is made

5) GRINDING Figure 1-10

•This process involves the final size being machined of the

piston. The grinder machines the skirt of the piston

6) Final Inspection
At this stage the piston is cleaned, fitted with the appropriate
wrist pin, stamped with the pistons oversize and any other
markings, and then sent to dispatch.

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 Manufacturing by Forging

1 ) THE ROD
•The piston begins as a three meter, solid aluminum rod. The reason
aluminum is used is that it's lightweight, rust-proof, and easy to cut.
• A saw then cuts the rod into smaller pieces called slugs.
2) The Punch
• A punch press and dye are pre-heated while the slug moves through an
oven, heating it to 426 C° as the punch press.

• The slug is then removed from the oven, and placed into the punch.
The press applies 2,000 tons of pressure onto the slug, forging it into
the basic shape of a piston.

• This process causes the piston to become so hot, that it needs hours
to
Cool

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 Figure 1-11

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4) The Wrist Pin Holes and oil control holes
• A large hole is then drilled through both sides of the piston. This is
where the wrist pin will go, attaching the piston to the connecting rod
• Oil control holes are drilled along the

5) Ring Grooves
Three ring grooves are created by a Lathe machine

Figure 1-12

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 Figure 1-13

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 Grinding )5
•The next step involves grinding of the piston from it’s head to give the crown the shape
required according to the design . A lubricant is used to cool the work piece continuously.

Figure 1-14

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 Finishing the Job )6

•Another lathe shaves a few more millimeters off of the top, allowing the
piston to expand when heat builds up inside of it. Then a machine
engraves model and production information.

•A human worker then smooths out the sharp edges of the piston created
during production

•Finally, the pistons sprayed by hot, deionized water, removing any

lubricant or oil gathered through the manufacturing process. After they're
dry, they're ready for use

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DIFFERENCE BETWEEN FORGED AND CAST PISTONS

CASTED PISTONS FORGED PISTONS

They are affordable . They are expensive
Lighter weight because of the
Aluminum alloy . Mostly used for high speed
It is generally used for slow Speeds. or high rpm’s

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 Types of pistons

:In engine of cars -1

Figure 1-16

Figure 1-17

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 CONCLUSION

A piston is a component of reciprocating engines, reciprocating pumps, gas

compressors and pneumatic cylinders, among other similar mechanisms. It is the
moving component that is contained by a cylinder and is made gas-tight by piston
rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder
to the crankshaft via a piston rod and/or connecting rod. In a pump, the function is
reversed and force is transferred from the crankshaft to the piston for the purpose of
compressing or ejecting the fluid in the cylinder. In some engines, the piston also acts
.as a valve by covering and uncovering ports in the cylinder

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 References

.Magda, Mike. "What Makes A Racing Piston?". Retrieved 2018-04-22

Bailey, Kevin. "Full-Round vs. Strutted: Piston Forging Designs and Skirt Styles
.Explained". Retrieved 2018-07-15
.Ricardo (1922), p. 116
.Ricardo (1922), p. 149
Piston with improved side loading resistance, 2009-10-12, retrieved 2018-04-22
.Ricardo (1922), pp. 119–120, 122
.Irving, Two stroke power units, pp. 13–15
.Irving, Two stroke power units, pp. 15–16
uliccylinder-china.com/hydraulic-cylinder/arm-cylinder/ex220-5-ar
ml

http://www.myschoolhouse.com/courses/O/1/143.asp

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