TRAINING REPORT ON

FEDERAL MOGUL GOETZE INDIA BAHADURGARH (PATIALA)

Submitted by: Neeraj goyal DIP

103710

CONTENTS
TRANING CERTIFICATE PREFACE ACKNOWLEDGEMENT COMPANY PROFILE INTRODUCTION TO R.M.S(RING MACHINE SHOP)

 TRANING REPORT

ACKNOWLEDGEMENT
Before we get into thick of things I would like to avail this opportunity to thank Mr.V.K. MALHOTRA (training & placement officer) who permitted & guided me in my two months training at Goetze (India) ltd. Infact it would be futile to express my obligations in black & white for the guidance provided. It was great pleasure & privilege to have got an opportunity to undergo 2 month training at a company of such a stature. I am sure that the knowledge & information that I have gained during this period growth in would be immense value for my the field of MECHANICAL ENGGINEERING.

I enunciate my abysmal indebt ness to Mr.YADWINDER SINGH for their priceless & inestimable facilitation in the absence of which this accomplishment could not be brought in situation.

NEERAJ GOYAL

INTRODUCTION
GOETZE (I) LIMITED, BAHADURGARH was set up in 1954 with the collaboration of M/S GOETZE WERKE, GERMANY, which started its production of Piston Rings for automobile industry in 1957. Considering the need of complete PISTON assembly ESCORTS LIMITED ventured into manufacturing of Pistons. In 1958 with the collaboration of M/S MAHLE GmbH, GERMANY, this delivered the Indian automobile industry its Piston in 1960. ESCORTS entered in collaboration with M/S SUKO GmbH, GERMANY, for Piston Pins in 1967 and manufacturing started in 1968.To meet the increasing demand of market, in 1977 a parallel unit for manufacturing Pistons and Pistons Pins was set up in BANGLORE. Technological leadership matched with innovated thinking has made ESCORTS and GOETZE products to enjoy a high degree of customer confidence and is the first choice of discerning for application ranging from BI-WHEELER to BATTLE TANKS. The plant manufacture over 3.4 million & 2.9 million Piston-Pins & Crank Pins annually .Around 50% of its production is being fitted by original equipment manufacturers of Automobile, Bi-wheelers, Tractors, Stationary Engines, Generator etc. Among its biggest customers are the MUL for which it manufactures pistons for Maruti-800, Esteem, Zen etc. Other customers include Peugeot, Escorts Division-Faridabad, Bajaj, Vespa, Hindustan Motors, TVS, Rajdoot and many others. The company also directly supplies its products to all the authorized dealers of the spare part for the above companies throughout INDIA. From 1st October, 1996, ESCORTS LIMITED entered into joint venture with M/S MAHLE GmbH, GERMANY with the formation of new company, ESCORTS In June 2000, both ESCORTS MAHLE LIMITED and GOETZE have become QS

9000 certified companies. Wide range of pistons and pins are also exported to U.K., Iran, Bangladesh, Sri-lanka, Egypt, Singapore and Malaysia.

IMPORTANT PRODUCTS:
Tractors: Escorts in Indias largest manufacture of tractors. In 25-50 HP range including the internationally lone FARMTRAC.
Motorcycles: A classic Escorts success story in relevant technology is the Rajdoot 175 cc motorcycle, a product of steady evaluation spanning a quarter century. Industrial equipments: The escorts range of world class products include rough terrain and pick and carry hydraulic mobile cranes in the 3 to 40 tones range, loaders, vibratory rollers and industrial haulers and tuggers etc. Escorts sell the largest no. of mobile cranes in India in addition to its largest export commitments. Automotive Ancillaries: Escorts products the widest range of piston assemblies for automotive, railways, D.G. sets, Battle tanks in India and for other applications also .The Goetze rings covers the wide range in standard in standard and specialization material in chrome plated and molybdenum plated conditions. Railway Ancillaries: Escorts is helping Indian railways and the other networks around the world to meet the challenges of future. The range includes the vacuum and electro pneumatic braking system, center buffer couple, double acting hydraulic shock absorbers, large diameter pistons & rail fastening systems

Organization Chart
Goetze (INDIA) LIMITED

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RING MACHINE SHOP

Ring machine shop is a production unit at Goetze India Limited, Bahadurgarh. In this shop special purpose dedicated machines are used for the processing of ring blanks (rings obtained from foundry) to the finished rings as per requirements of the customer. Ring machine shop has strength of approx. 500. Some machines run around the clock.

SECTIONS OF RING MACHINE SHOP

Ring machine shop is divided into the following sections:1.ROUGH SECTION : - It is the first section where the ring comes for operation from store. It mainly does the rough operations on all the rings. Ring is completely machined from all the sides before it leaves the section. 2.FINISH SECTION : - It mainly does the operations after rough operation. It gives the finishing operations to all the non-chrome rings. 3.CHROME FINISH SECTION : - It mainly does the operations after rough operation. It gives the finishing operation to the chrome rings. 4.MOLY SECTION : - It is a very important section of not only ring machine shop but also the GOETZE INDIA LTD. In this section a coating of

molybdenum is done on the rings. Moly is a said for molybdenum coating which is fed in the form of a wire, the wire is then melted and sprayed on the rings. It is done to avoid the scuffing and to increase the life of the rings.

5. COIL WINDING SECTION: - This section prepares the ring for the molysection. A coil is formed which is compressed in a mandrel. It is used for two diameters i.e., 83&97mm. the material is steel. This is a highly produced ring of the moly-section. It has three types of machines:1. Coil winding machine. 2. Gap cutting machine.

7. QUALITY CONTROL OR INSPECTION DEPARTMENT :-.

This department is concerned about the quality and inspection.

INSPECTION
All the type of rings finally comes to this department for inspection and it here that they are finally classified as good scrap and rework rings. The good rings are finally sent to the dispatch section.

QUALITY
The quality is measured from the filled charts. It is the responsibility of this section that the charts in the entire shop should be filled properly. Because only from these charts the interpretations can be visualized and the corrective actions can be sorted out. From here it is found that where the fault is lying whether with the machine or with the operator.

RING CONSTRUCTION

BASIC FUNCTIONS OF PISTON RINGS

Piston rings have three main functions as below: * TO SEAL WORKING CHAMBER FROM CRANCKCASE. * TO COOL PISTON BY ASSISTING FLOW OF HEAT TO CYLINDER LINER. * TO CONTROL OIL CONSUMPTION.

The piston rings in I.C Engines have to perform the following functions: To form a seal for the high pressure gases from the combustion chamber against leak into the crankcase. To provide easy passage for heat flow from the piston crown to the cylinder walls. To maintain sufficient lubricating oil on the cylinder wall throughout the entire length of the piston travel, minimizing the ring and the cylinder wear. And at the same time, control the thickness of the oil film so that satisfactory oil control is maintained. The oil is not to be allowed to go up to the combustion chamber where eventually it would burn to leave carbon deposits. The rings are installed in grooves in the piston. Actually, there are two types of rings, compression rings and control rings. The compression rings seal in air-fuel mixture as it is compressed. They also seal in the combustion pressure as the mixture burns. The oil control rings scrape excessive oil from the cylinder wall and return to the oil pan. The rings have joints so they can be expanded and slipped over the piston head and

grooves into the piston. Rings for automotive engines usually have butt joints. In some heavy-duty engines, the joint may be lapped, or of the sealed type. The rings are slightly larger than in diameter than they will be in cylinder. Then, when the rings are installed, they are compressed so that the joints are nearly closed. Compressing the rings outs them in tension. Then they press tight against the cylinder wall. The distance between the ends of the rings when it is compressed in the cylinder is called the ring gap.

RING TERMS AND MEASUREMENTS

A. Free gap: - The ring end clearance when the ring is uncompressed. B. Compressed gap: - Also known as ring gap, it is the end gap measured when the ring is installed. C. Radial Wall Thickness: - the distance between the inside and outside faces of the ring wall. D. Ring Diameter: - Measured with the ring installed. E. Inside Diameter: - Measured with the ring installed. F. Ring Sides: - Top and bottom surface of the ring. G. Ring Face:-The part of the ring in contact with the cylinder wall. H. Side Clearance:-Clearance between the ring groove and the ring. I. Ring Width:-It is the axial width of the ring. J. Torsional Twist:-A built-in imbalance between the way the upper and lower sides compress that causes a twist in the ring when compressed. Used to sea both the ring in the groove and the ring to the cylinder wall. K. Back Clearance:-Distance between the inside diameter of the ring and the bottom of the ring groove with the ring installed.

VARIOUS OPERATIONS DONE IN RING M/C SHOP

INSIDE CHAMFERING

OUTSIDE CHAMFERING MACHINE STAMPING GROOVING SLOTTING GAP SIZING BEVELLING INSIDE GROOVING

FINISH TURNING

NOTCH MILLING LAPPING

VARIOUS MACHINES USED IN THE RING SHOP

1. ROUGH GRINDING:Rings obtained from foundry have poor surface finish and less dimensional accuracy. Ring blanks are grinded axially to achieve the dimensions required. To grind rings axially center-less grinding machines are used. These are very robust, rigid, heavy machines. In this process Ring blanks are fed through a magnetic feeder to the two revolving grinding wheels, separated by a distance which is equal to the thickness of the ring required. Axial width grinding is carried out in two or three stages as per requirement and different special purpose, dedicated centre-less grinders are used for grinding the ring blanks to achieve required size as per process sheet.

i.

BESLY/HMT ROUGH GRINDING MACHINE

Used for rough/medium grinding of axial width of rings Working principle is centre less grinding with horizontal spindles Parameter controlled is axial width of ring Manpower 2 persons per shift Angle between grinding wheels 3 to 5 Coolant used CIM cool (6-10%) mixed with water

ii.

KAEFIG (CNC) FINISH GRINDING MACHINE

Used for finish grinding of axial width of rings

Working principle is centre less grinding with horizontal spindles Parameter to be controlled is axial width of rings Manpower 2 persons per shift Angle between grinding wheels - 3 to 5

iii.

DFS FINISH GRINDING MACHINE

Used for finish grinding of axial width of rings Working principle is centre less grinding Parameter to be controlled is axial width of rings Manpower 2 persons per shift Angle between grinding wheels- 3 to 5

2. DCT(TURNING AND BORING)

Outside turning and inside boring is a very important process. In this process turning and boring are done simultaneously. This step is of maximum importance because a number of parameters are dependent on this operation. These are:

Major Diameter Minor Diameter Radial Thickness Ovality Closed Gap (after gap cutting) Free Gap (after gap cutting) Tangential thickness Light passage

 Visual appearance

Rings in the form of packets (30 -80 rings per packet) are aligned on the horizontal bar with a wire rotating with a motor. Ring packet is aligned such that flat surface faces upwards. After aligning, rings are held in a clamping device called carrier, then ring packet is moved to the machine spindle and is clamped pneumatically. At a time, six cutting tools are mounted, three tools on boring bar for internal cutting and three on tool post for external turning. The usage of three tools in single pass allows saving of time and good results. Selection of cam to suit the ovality of rings is mentioned on process sheet. Machines used for turning and boring are named as DCT (Double Cam Turning) machines. These are 15 in number in the ring machine shop. These machines are semi-automatic. One operator is employed for each machine. After turning and boring the ring is clamped on carrier and removed from machine spindles by releasing the air pressure and moved to gap cutting machine.

3. GAP CUTTING
Gap cutting operation is performed on the same station as of turning and boring. It is a semi-automatic machine. In gap-cutting, the rings are held pneumatically in gap-cutting machine and a milling cutter is used to cut the gap in two passes. In first pass, one end of gap is cut with a rotating cutter and the cutter is then moved backwards. The other end of the gap is then aligned with the cutter, and this step is a part of the automatic cycle of the machine. The cutter then cuts the other end and the gap is cut in all rings in a packet. Cutter then moves backwards and all the rings are unloaded from the machine manually by releasing air pressure.

4. AXIAL WIDTH INSPECTION

This machine is basically an inspection machine. Ring is loaded from one side and in an arrangement which pushes the ring one by one under an axial width checking instrument. Then this arrangement separates out the good, over-size, &under-size rings. Thus all these categories of rings are collected separately.

5. GAP SIZING MACHINE

Gap cutting operation is performed after finish turning. In gap-cutting the rings are held like the operations of axial width and stamping machines. This is the only operation after gap cutting it gives the finishing touch to the gap. In this procedure a cutter having teeths on its surface is rotated and the rings are pushed with the help of a ram against it and the gap is made of the required size. The loading and unloading are same as the axial width and stamping machines. 6. GROOVING MACHINE The process of grooving is done after stamping. This process is carried out only for the oil piston rings and not for the compression rings. In this process firstly the rings are closed with the help of compressed airs pressure which is used to close their gaps so that while the process of grooving the grooving tool should not interfere with the gap. The tool used for grooving is a multi-tool which is used to save the time. The grooves are on the outside of the ring surface it takes the oil in it during its function in the piston ring assembly. These machines are four in number. INSIDE GROOVING M/C: This process is very sophisticated so it is carried out on the CNC machine in which a bunch of rings is placed in a die, suitable to the size of rings, and is rotated. Thus the process is carried out and inside grooving is done.

SECTIONS OF RING MACHINE SHOP

ROUGH SECTION
It is the first section where the rings come for operation from store. It mainly does the rough operations on all the rings. Ring is completely machined from all the sides before it leaves the section.

The rough section includes the axial grinding of the ring blanks received from the piston ring foundry along with the process sheet

FINISH SECTION
It mainly does the operations after rough operation. It gives the finishing operations to all the non-chrome rings.

COIL WINDING SECTION

This section prepares the ring for the molly-section. A coil is formed which is compressed in a mandrel. It is used for two diameters i.e., 83&97mm. the material is steel. This is a highly produced ring of the molly-section.

 It has two types of machines: Coil winding machine. Gap cutting machine.

QUALITY CONTROL OR INSPECTION DEPARTMENT

This department is concerned about the quality and inspection.

INSPECTION: All the type of rings finally comes to this department for
inspection and it here that they are finally classified as good scrap and rework rings. The good rings are finally sent to the dispatch section.

QUALITY

The quality is measured from the filled charts. It is the responsibility of this section that the charts in the entire shop should be filled properly. Because only from these charts the interpretations can be visualized and the corrective actions can be sorted out. From here it is found that where the fault is lying whether with the machine or with the operator.

TOOL STORE
All the tools and equipments necessary for the shop are taken from here and it the responsibility of this store that every operator should get the requisite tools and other essential commodities

VARIOUS MACHINES USED IN THE RING SHOP

1. ROUGH GRINDING
Rings obtained from foundry have poor surface finish and less dimensional accuracy. Ring blanks are grinded axially to achieve the dimensions required. These are very robust, rigid, heavy machines. In this processing blanks are fed through a magnetic feeder to the two revolving grinding wheels, separated by a distance which is equal to the thickness of the ring required.

2.

DCT(DOUBLE CAM TURNING)

Outside turning and inside boring is a very important process. In this process turning and boring are done simultaneously. This step is of maximum importance because a number of parameters are dependent on this operation. These are: a. Major Diameter b. Minor Diameter c. Radial Thickness d. Ovality e. Closed Gap (after gap cutting) f. Free Gap (after gap cutting) g. Tangential thickness

h. Light passage i. Visual appearance

3.

GAP CUTTING

Gap cutting operation is performed on the same station as of turning and boring. It is a semi-automatic machine. In gap-cutting, the rings are held pneumatically in gap-cutting machine and a milling cutter is used to cut the gap in two passes.

4.

STAMPING MACHINE

This machine puts a stamp on the rings of the company like GOE. This has the same loading and unloading arrangement as that of the axialwidth machine.

5.

COIL WINDING MACHINE

In this machine a coil is formed which is compressed in a mandrel. It is used for two diameters i.e., 83&97mm. the material is steel. This is a highly produced ring of the molly-section. Measurement is done by Vernier Caliper. Speed is kept at 10.42 m/min for all diameters.

6.

GROOVING MACHINE

The process of grooving is done after stamping. This process is carried out only for the oil piston rings and not for the compression rings. In this process firstly the rings are closed with the help of compressed airs pressure which is used to close their gaps so that while the process of grooving the grooving tool should not interfere with the gap. The tool used for grooving is a multi-tool which is used to save the time. The grooves are on the outside of the ring surface it takes the oil in it during its function in the piston ring assembly. These machines are four in number.

7.

LAPPING MACHINE

The lapping machine does the operation on the axial width of the ring. It operates 25 rings in a go. The two grinding wheels are operated at a quite high speed. The upper grinding wheel is lifted and the rings are unloaded. It uses cutting oil which is also termed as coolant as kerosene oil. Lapping operation is a super finishing operation. It is done with the help of machine named HELLER-HYDRAULIC. The machines consist of head rotating in opposite directions. Both these heads have lapping stones attached to them. The axial width is controlled by varying the pressure of upper head and amount of kerosene supply. Metal removal rate can be increased or decreased. The timer is also attached to the machine for timing the process depending upon the size of cut.

8.

HONING MACHINE
This machine does the finishing operation on the rings but the material removal is the smallest from all other operations in the ring machine shop. The rings are placed in a packet of 15-20 depending on the size. Honing machine is another super finishing operation and also to provide good finish. It is done after first lapping. In this process the outer surface of the rings is polished. The set of rings are fixed on a tool and the tool is attached with a hydraulic ram, which moves up and down simultaneously revolves. The tool reciprocates and revolves in a sleeve.