TERM PAPER ON STUDY OF VALVE

LEAKAGE IN AN IC ENGINE

In partial fulfilment of th rquirmnts for th wrd of th Dgr of

Bchlor of Tchnology in

MCHNICL ND UTOMATION

By

SOURABH RAJ SHUKLA

7605414047
B.Tch (M), 7th smstr

Under th guidance of

MR. ASHOK VERMA

SST.PROFSSOR, ST

Submitted to:
DPRTMNT OF MCHNICL ND UTOMTION
NGINRING

MITY SCHOOL OF NGINRING ND TCHNOLOGY

 MITY UNIVRSITY, LUCKNOW
UTTR PRDSH

CKNOWLDGMNT

prt from my fforts, th succss of this projct dpnds lrgly on th ncourgmnt nd

guidlins of mny othrs. I tk this opportunity to xprss my grtitud to th popl who
hv bn instrumntl in th succssful compltion of this projct. I would lik to show my
grtst pprcition to Ashok verma sir and j p singh who have helprd me a lot in the
completion of the project.

I would lso thnk my Institution, Hd of th Institution nd my fculty guid mr Ashawani

sharma , SST. PROF., ST without whom this projct would hv bn distnt rlity.
I lso xtnd my hrt full thnks to my fmily nd wll-wishrs.

NM: SOURABH RAJ SHUKLA

COURSE: BTECH (MAE) VI-SEM

NROLLMNT NO.-7605414047
STUDY OF VALVE LEAKAGE IN SIX
CYLINDER INTERNAL COMBUSTION

An IC engine has four main parts via. Cylinder head,cylinder block,shaft and shaft block. In
tata motors ,the manufacturing of an IC engine had manufacturing of these four parts. My
project was on cylinder head so I 1st studied the manufacturing process of cylinder head and
also got to know about valve leakage,its introduction, how to reduce it etc. The valve of an
ABOUT TATA MOTORS

Tata Motors Limited, a USD 42 billion organisation, is a leading

global automobile manufacturer with a portfolio that covers a wide
range of cars, sports vehicles, buses, trucks and defence vehicles.
Our marque can be found on and off-road in over 175 countries
around the globe.

1945TATA MOTORS Established

60,000Employee Strength
$42 BillionCompany Turnover
>9 MillionVehicles Sold
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Tata Motors is part of the USD 100 billion Tata group founded by Jamsetji Tata in 1868. Sustainability
and the spirit of giving back to society is a core philosophy and good corporate citizenship is strongly
embedded in our DNA. Tata Motors is Indias largest automobile company. We bring to the customer
a proven legacy of thought leadership with respect to customer-centricity and technology. We are
driving the transformation of the Indian commercial vehicle landscape by offering customers leading
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and our activities and that is our mission to be passionate in anticipating and providing the best
vehicles and experiences that excite our customers globally''.
SAFETY
Safety is the most important priority of tata company.on first day of my internship we had
a 1 hour class on safety. InThere are two slightly different meanings of safety. For
example, home safety may indicate a building's ability to protect against external harm
events (such as weather, home invasion, etc.), or may indicate that its internal
installations (such as appliances, stairs, etc.) are safe (not dangerous or harmful) for its
inhabitants.

Discussions of safety often include mention of related terms. Security is such a term. With
time the definitions between these two have often become interchanged, equated, and
frequently appear juxtaposed in the same sentence. Readers unfortunately are left to
conclude whether they comprise a redundancy. This confuses the uniqueness that should
be reserved for each by itself. When seen as unique, as we intend here, each term will
assume its rightful place in influencing and being influenced by the other.

Safety is the condition of a steady state of an organization or place doing what it is

supposed to do. What it is supposed to do is defined in terms of public codes and
standards, associated architectural and engineering designs, corporate vision and mission
statements, and operational plans and personnel policies. For any organization, place, or
function, large or small, safety is a normative concept. It complies with situation-specific
definitions of what is expected and acceptable.
CONTENTS

CYLINDER HEAD LINE

VALVE LEAKAGE IN AN IC ENGINE
VALVE LEAKAGE REPORT,FEB 2017
VALVE LEAKAGE REPORT,MARCH 2017
VALVE LEAKAGE REPORT,APRIL 2017
VALVE LEAKAGE REPORT,MAY 2017
GRAPH
FINAL REPORT
CONCLUSION
CYLINDER HEAD LINE

STATION 1: LOADING POINT

OPERATION DESCRIPTION: Received semi finished material from store kept in pallets and loading on
entry conveyor . Application of antirust oil and job is separated from oil soaked foam. The defected
on ajob is marked and hold for further finishing.

PROCESS SPECIFICATION: (1) rust free

(2) no casting defects

(3) Dent free machined surface

STATION 2: PARENT BORE OPERATION

OPERATION DESCRIPTION: Valve seat and valve guide parent bore finishing operation and semi finish
milling. Tool setting and prechecking of tool is done in presetter.Tool offset setting is done in
machine. Also a visual inspection is done after parent bore operation.

PROCESS SPECIFICATION: (1) diameter of outlet valve seat parent bore- 38+0.025 mm

(2) diameter of inlet valve seat parent bore-45+0.025 mm

(3) Valve guide parent bore diameter-15+0.018 mm

 (4) depth of inlet valve seat parent bore- 11.7+/-0.1

(5) depth of outlet valve seat parent bore-11.1+/-0.1

(6) thickness of head- 92025+/-0.05

STATION 3: INTERMEDIATE WASHING

OPERATION DESCIPTION: washing (intermediate) of job after machining operation. Job should be
totally clean of burrs. High pressure washing is done for 3 minutes with ambient fluid pressure.
Timer inbuilt in machine and alarms for error proof.

PROCESS SPECIFICATION: (1) No burrs or metallic chips

(2) washing time- 3 minutes

(3) Fluid pressure- 13-17 kg/cm square

(4) Fluid temperature- ambient temperature

STATION 3: CORE PLUG PRESSING

OPERATION DESCRIPTION: Application of anabond and core plug pressing . pneumatic impact tool
hammer is used for the process. Manual pressing of core plug is done with dolley and impact
hammer. Proper application of anabond is very important.Core hole inspection is done after the
process.

PROCESS SPECIFICATION: (1) leak proof

(2) core plug should not be above the exhaust face

(3) core plug should not be above the rocker face milling

(4)core hole- 27 dia H9

STATION 5: PLUG TIGHTENING

OPERATION DESCRIPTION: Tightening of plug with proper torque. CP machine is used for the
process. Proper application of putty and anabond is done during the process.Torque selection for
different plugs from socket selection tray is in built in the machine. Leak testing is also done after the
process.

PROCESS SPECIFICATION: (1) 7-15 mkg torque for M24 & M22, 10-20 torque for M30

(2) No damage of plug due to socket wea rout

(3) Leak proof

STATION 6: LEAK TESTING
OPERATION DESCRIPTION: Leakage testing is done by checking leakage rate after filling air pressure
in the valves and leak free cylinder heads are obtaines after the process.

PROCESS SPECIFICATION: (1) checking leakage rate- +- 2 ccc/min

(2) filling air pressure= 1.5 bar

(3) incoming air pressure= 5-7 bar

STATION 7: VALVE SEAT PRESSING

OPERATION DESCRIPTION: Heating of component is done after which valve seat ring pressing is done
in the parent bore.heating tub is used with water of temperature 60-80 degree celsius. First the
component is heated in water for 2 to 3 minutes after which cooled valve seat rings(by dipping in
liquid nitrogen) are adjusted in the valves through hammers.proper seating of valve seat ring is very
important.

PROCESS SPECIFICATION: (1) Water temperature- 60 to 80 degree celcius

(2) Water level should cover parent bore area

(3) proper cooling of valve seat rings for 2 to 5 minutes

(4) proper seating of valve seat rings without any gap

(5) dolley should be free from any dent or damages

STATION 8: VALVE GUIDE PRESSING

OPEREATION DESCRIPTION: Valve guide pressing is done through hydraulic press. correct valve guide
is taken for inlet and exhaust bore and is pressed perfectly using the hydraulic press. Height of the
valve guide from the spring seat is to be maintained. Grooves are made in the ram for equal height
pressing. Visual inspection of equal height of the valve guides is also done. Error proofing is done on
the exit conveyor for equal heights.

PROCESS SPECIFICATION: (1) correct selection of inlet and exhaust valve guides

(2) height of the valve guide from the spring seat- 20-0.5 mm
STATION 9: VALVE SEAT AND VALVE GUIDE FINISHING

OPERATION DESCRIPTION: Finishing reaming of valve guide bore (8 dia and 10 dia) and finishing
chamfering of valve seat is done. The job is carried by a robot from the conveyor to the machine
where machining operations are done on the job. The tool is regularly changed after every 30 job for
better machining operation and end of tool life. Coolant is used with a pressure of 2-5 bar for better
finishing. After machining the robot again carries the job from the machine to the conveyor belt for
inspection purposes.

PROCESS SPECIFICATION: (1) Diameter of outlet valve- 10+0.22 mm

(2) Diameter of inlet valve- 9+0.22 mm

(3) Depth of valve seat- 0.9+/0.2

(4) Valve seat blue contact- 100%

(5) No blue hole

(6) No valve guide crack

VALVE LEAKAGE IN AN IC ENGINE
VALVE LEAKAGE REPORT,FEB 2017

VALVE LEAKAGE REPORT , FEB. 2017

RANGE NUMBER OF NUMBER OF NUMBER OF NUMBER OF NUMBER OF NUMBER OF

OF CMPONENTS CMPONENTS CMPONENTS CMPONENTS CMPONENTS CMPONENTS
LEAKAGE B1 B2 B3 B4 B5 B6
0-50 647 1300 681 1058 1132 1300

50-100 358 0 285 145 56 0

100-150 189 0 208 46 40 0

150-200 95 0 107 34 45 0

ABOVE 11 0 19 17 27 0
200

Note- Leakage Range is in

ml/min
VALVE LEAKAGE REPORT,MARCH 2017

RANGE NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER

OF OF OF OF OF OF OF
LEAKA CMPONEN CMPONEN CMPONEN CMPONEN CMPONEN CMPONENT
GE TS B1 TS B2 TS B3 TS B4 TS B5 S B6
0-50 933 1547 1176 1316 1356 1547
50.01- 365 0 207 142 103 0
100
100.01- 147 0 105 59 54 0
150.01
150.01- 78 0 46 23 23 0
200
ABOVE 24 0 13 7 11 0
200

Note- Leakage Range is

in ml/min
VALVE LEAKAGE REPORT,APRIL 2017

RANGE NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER

OF OF OF OF OF OF OF
LEAKAG CMPONEN CMPONENT CMPONEN CMPONEN CMPONENT CMPONEN
E TS B1 S B2 TS B3 TS B4 S B5 TS B6
0-50 891 1306 1129 1073 921 1308
50.01- 195 2 92 150 201 0
100
100.01- 125 0 60 45 95 0
150.01
150.01- 59 0 21 31 60 0
200
Above 38 0 6 9 31 0
200
VALVE LEAKAGE REPORT,MAY 2017

RANGE NUMBER NUMBER NUMBER NUMBER NUMBER NUMBER

OF OF OF OF OF OF OF
LEAKAG CMPONEN CMPONEN CMPONENT CMPONENT CMPONENT CMPONEN
E TS B1 TS B2 S B3 S B4 S B5 TS B6
0-50 890 734 777 1015 1070 1277
50.01- 283 236 244 157 101 0
100
100.01- 65 178 154 66 82 0
150.01
150.01- 35 121 96 34 22 0
200
200-400 4 8 6 5 2 0
Note- Leakage Range is
in ml/min
FINAL REPORT

1. The manufacturing of cylinder block was

okay
2. The milling machine had fault and made
valves of wrong dimensions
3. There was no problem in the manufacturing
process other than milling machine.
CONCLUSION

Finally I got to learn a lot about ic engine,its manufacturing and working.i would like to
thank my guide Mr Ashok verma who taught me a lot about IC engine and me in my
project. This was a very tuff project for a 1st time internship. Finally I got to know that the
valve leakage that was introduced in the cylinder block was due to fault in the
manufacturing process. The milling machine that used to make valve holes in the cylinder
block had fault and was woking in a wrong angle. This made valves of wrong dimensions
and due to which the valve of the cylinder block had leakage of energy.