AT6006

MANUFACTURING OF AUTOMOTIVE COMPONENTS

L T P C
3 0 0 3

OBJECTIVES:
To impart knowledge on basic principle and production methods of automotive components.
UNIT I CASTED ENGINE COMPONENTS
9
Material selection and Manufacturing methods for Piston, Piston rings, Cylinder block, wet and
dry liners, Engine head, Oil pan, Carburetors. Thermal barrier coating of Engine head and
valves.
UNIT II FORGED ENGINE COMPONENTS
8
Material selection and Manufacturing methods for Crank shaft, Connecting rod, Cam shaft,
valve, Piston pin, Push rod, Rocker arm, tappets, spark plug.
UNIT III TRANSMISSION SYSTEM
10
Material selection and Manufacturing methods for Clutch Clutch lining Gear Box Gear
Propeller Shaft Differential Axle Shaft Bearing fasteners Wheel drum. Methods of Gear
manufacture Gear hobbing and gear shaping machines - gear generation gear finishing and
shaving Grinding and lapping of hobs and shaping cutters gear honing gear broaching.
UNIT IV VEHICLE CHASSIS
8
Material selection and manufacturing methods for chassis, dead axle, leaf spring, coil spring and
shock absorbers wheel housing steering system, Brake shoes, wheel rim, Tyres. Heat
treatment procedures.
UNIT V RECENT DEVELOPMENTS
10
Surface treatment Plastics Plastics in Automobile vehicles Processing of plastics - Emission
control system catalytic converter Hydro forming of exhaust manifold and lamp housing
stretch forming of Auto body panels MMC liners Selection of materials for Auto components.
Use of Robots in Body well-meant.
TOTAL: 45
PERIODSOUTCOMES
Upon completion of this course the student can able to use the basic principle and production
methods of automotive components
TEXT BOOK:
1. Heldt.P.M, "High speed combustion engines", Oxford publishing Co., New York, 1990.
REFERENCES:
1. Kirpal Singh, 'Automobile Engineering", Vol. I & II, Standard Publishers, New Delhi, 1997.
2. Newton and steels, the motor vehicle, ELBS, 1990
3. Serope Kalpakjian and Steven R. Schmid, "Manufacturing Processes for Engineering
Materials", Fourth Edition, Pearson Education publications 2003
4. Gupta K.M. "Automobile Engineering" Vol.I & II, Umesh Publishers, 2000.

CONTENTS
Unit I Casted Engine Components
Manufacturing Introduction
1.1. Piston
1.1.2. Piston Material and Selection
1.1.2. Piston Ring
1.1.3. Main Functions of Piston Rings
1.2. Ring Rings (Categories)
1.2.1. Piston Ring Materials and Coatings-16
1.3. Engine Blocks
1.3.1. Required Material Properties
1.3.2. Manufacturing the Cylinder Block
1.4. Cylinder Liner
1.4.1. Dry Liners
1.4.2. Wet Liners
1.5. Engine Head
1.5.1. The Casting Methods
1.6. Oil Pan
1.6.1. Quality Manufacturing
1.7carburetors
1.7.1. Carburetor Material
1.8. Thermal Barrier Coating Of Engine Head And Valves
1.8.1. Thermal Barrier Coating In Diesel Engine

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Unit II Forged Engine Components

2.1. Crankshafts
2.1.1. Flexible Forming Tool
2.2. Connecting Rod
2.2.1. Introduction to Manufacturing Method Optimization
2.3. Camshaft
2.3.1. Cam Shape
2.3.2. Motion of the Cam
2.3.3. Materials Used In Camshaft
2.3.4. Methods of Manufacturing

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2.4. Valves
2.4.1. Materials
2.4.2. Manufacturing Processes
2.5. Piston Pin
2.6. Pushrods
2.7. Rocker Arm
2.7.1. Types Of Rocker Arm
2.7.2. Materials
2.8. Spark Plug
2.8.1. Raw Materials
2.8.2. The Manufacturing Process

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Unit III Transmission System

3.1Clutch
3.1.1. Manufacturing Process Of A Car Clutch
3.2. Gear
3.2.1. Gear Manufacturing
3.2.2. Materials

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Unit IV Vehicle Chassis

4.1. Chassis
4.1.1. Requirements of The Materials In Automotive Design
4.1.2. Chassis Manufacturing Process
4.2. Dead Axle
4.3. Leaf Spring
4.3.1. Raw Material
4.3.2. Spring Manufacturing Process
4.3.3. Short Order Department
4.3.4. Shock Absorbers
4.3.5. Manufacturing Processes & Machines Generally Used
4.4. Steering System
4.1.1Aluminum Components Of The Steering System
4.5. Brake Shoes
4.5.1. Brake Disc
4.5.2. Material Selection Of Components Using Cass Software
4.5.3. Manufacturing Route Of The Components

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4.5.4. Manufacturing Of Advanced Material

4.6. Wheel
4.6.1Wheel Materials
4.7. Tire
4.7.1. Raw Materials Used
4.7.2. Tyre Manufacturing Process

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Unit V Recent Developments

5.1. Surface Treatment
5.2. Plastics Processing
5.3. The Basic Elements Of Tubular Hydroforming
5.4. Sheet Metal Forming - Stretch Forming
5.5. Metal Matrix Composites
5.5.1Selection Of Materials For Auto Components
5.6. Types Of Robot Transporters

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