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INTERNSHIP REPORT
(10/12/2010 3/1/2011)
Submitted By: Muhammad Ali Khalid Muhammad Hammad Khan Muhammad Shoaib Idrees 2nd year students (Bachelors of Engineering) Department of Industrial & Manufacturing Eng. Ned University of Engineering & Technology
DEDICATION
We want to dedicate this project to our parents, and all our friends for being with us and helping us in each and every difficulty we faced in this project completion and to our teachers and all those who taught us, trained us and polished our abilities at Atlas Engineering Ltd.
ACKNOWLEDGEMENT
All praise unto Almighty ALLAH, the Lord of all worlds, who endowed us with the ability to complete successfully this period as internee, Though we did not conceal our self capable to do so
Group members Muhammad Ali Khalid Muhammad Hammad Khan Muhammad Shoaib Idrees
1- Engineering Sector 2- Trading Sector 3- Financial Sector 1- ENGINEERING SECTOR: The engineering sector includes the following listed companies 1- Atlas Honda Limited 2- Honda Atlas Cars (Pakistan) Limited 3- Atlas Engineering 4- Atlas Battery Limited 5- Atlas Power 2- TRADING SECTOR: The trading sector includes the following listed companies 1- Shirazi Trading Co. (Pvt.) Limited 2- Honda Atlas Power Product (Pvt.) Limited 3- Total Atlas Lubricant Pakistan (Pvt.) Limited 3- FINANCIAL SECTOR: Atlas Group has following three financial companies 1- Muslim Insurance Company Limited 2- Atlas Investment Bank Limited 3- Atlas Asset Management Co. Limited
ATLAS ENGINEERING:
Atlas Engineering Limited (formerly Allwin Engineering Industries Limited) was established in 1951 as a partnership firm. It became a private limited company in 1964, and a public limited company in 1967. The control of the company was acquired by the Atlas Group in 1981. At present, Atlas Engineering is one of the largest and oldest manufacturers of automotive parts and components in the private sector in Pakistan. Atlas Engineering has state-of-the-art facilities to produce Cast Iron process pig iron and aluminum alloys through various stages into high precision automotive components and has full access to technical know-how and back-up of world renowned manufacturers like the Shindengen Japan, F.C.C. Co. and Honda Foundry Japan. The Company manufactures diesel pistons, piston pins, cylinder liners/sleeves, motorcycle pistons, cylinders, CDI & Regulator, Pressure Die Casting, Aluminum Components, radiator assemblies and radiator cores and a host of fully-machined cast iron parts (both grey and ductile). These include brake drums, brake discs, flywheels and other high quality precision engineered components for all manufacturers of cars, light commercial vehicles, trucks, buses and tractors including Millat's Massey Ferguson and Al-Ghazi's Fiat Tractors, besides Honda, Suzuki, Toyota, Daihatsu and Hyundai cars, Nissan , Hino, Mazda, Dong Feng trucks & buses and Honda and Yamaha motorcycles. Atlas Engineering products are comparable with those of any international manufacturer and as such are also exported wherever demanded. Various assemblers have given excellence awards to Atlas Engineering for achievements in quality and delivery. The facilities at Atlas Engineering have been extended and modernized steadily over the last decade, and are amongst the best in the engineering sector of the country. As old machines are phased out, new machines including CNCs, and semiautomatic machining lines are being added. Further expansion of facilities for manufacture of piston and allied products pressure die casting and cast iron parts is being undertaken. The production facilities are backed by well-equipped quality assurance system, design and applied research facilities. Atlas Engineering policy and operations are guided by the management approach of Atlas Group, Organization development through self development. LOCATION & AREA:
Location Atlas Engineering is situated at 15th mile, National Highway,
FACILITIES: 1234567Melting (Cast Iron, Aluminum) Casting (Cast Iron, Aluminum) Machining (Cast Iron, Aluminum) Assembly (Radiator, CDI + Regulator) Quality Assurance Logistics Information Technology
LAB & OTHER FACILITIES: CAD, applied research facilities, coordinate measuring machine (CMM), Spectrometer standards room, chemical and metallurgical laboratories with which the company has built up a reputation for quality and reliability of supply. The company manufactures components for all leading manufacturers of the country as well as for the replacement parts market where its products compete favorably with established imported brands. Recognition of human resource as a key resource guides the company policy and operations. With emphasis on training and selfdevelopment the company is making strides towards creating a center of excellence. Staff are sent to prestigious certification of Pakistan for training and development. Further more continued education of staff is encouraged at higher level.
THE INTERNSHIP
Aluminum products department was our department of interest. An introductory visit started our internship. Diesel piston was made our product of study. Objective was to completely study the process followed by Atlas Engineering Limited in manufacturing diesel pistons and to give sound recommendations to improve the process with respect to cost effectiveness, production rate increment and control over rejection.
THE PLANT
Aluminum Products Plant at Atlas Engineering Limited is the purpose build plant which fulfils the needs of the company. Workers working in plant are very skilled persons; they show their devotion to work. Numerous quality products are manufactured here, including precision engine and body parts and pistons for diesel as well as petrol engine, pressure die components and other Aluminum components.
Millat Tractors
Piston, MF240
Al Ghazi Tractors
Piston FIAT
Other Parts
Bracket upper (L) Yamaha Crown handle Yamaha motorcycle
THE PROCESS
FLOW CHART:
RAW MATERIAL TESTING & STORAGE CASTING REJECTION MACHINING REJECTION FINAL INSPECTION STORAGE & DELIVERY The process followed by Atlas Engineering Ltd for making pistons has a logical flow i.e. the forward flow. Raw materials enter from one side of
the plant and complete pistons are delivered form the other side, only the scrap has the opposite flow.
RAW MATERIAL:
Mainly Aluminum is used for manufacturing pistons, where as, little quantities of other elements such as Silicon, Magnesium, and Iron also take part in piston manufacturing.
VIRGIN INGOTS:
Company purchases virgin ingots from different dealers. Since our project is related to diesel pistons so we will discus the composition of ingots purchased for diesel pistons. Mainly two types of ingots are purchased for diesel piston, namely, LM-13 & LM-28. LM-13 are purchased from SUN METAL (local dealer) and LM-28 imported from LUCKY ALLOY (Dubai). A single bundle contains up to 108 virgin ingots, weighs approx. 700 kg. Our piston of interest is of FIAT tractor, LM-28 type of ingots is used for manufacturing these pistons. Composition is shown below: Elements Si % Fe % 0.0 0 0.6 0 Cu % 1.3 0 1.8 0 Co % 0.00 0.50 Mn % 0.0 0 0.3 0 Na ppm 11.17 Mg % 1.0 0 1.3 0 Cr % 0.0 0 0.6 0 Ni % 0.8 0 1.3 0 Pb % 0.00 0.15 Zn % 0.0 0 0.2 0 Sn % 0.00 0.15 Ti % 0.0 0 0.2 0 Ca % 0.0010
Al %
78.7
SWARF INGOTS:
Swarf ingots are those ingots which are made by atlas itself from the chips which are removed from the piston in the machining operation and the slag and residue left in the furnaces. In these, usually the composition of magnesium decrease from the permissible limit, to over come this problem, few ingots of magnesium are also added along with swarf ingots.
CASTING:
In foundry, the casting starts from melting the ingots. Five electric furnaces are there in foundry for diesel pistons, out of which four were currently working for diesel pistons, where as, one was busy for child parts (due to there high demand). Furnaces have the capacity of max. 500 kg. Virgin ingots along with swarf ingots, runner, risers and magnesium ingots as per requirement are melted in the furnace. It takes around 1.52 hours in melting and degassing both. Degassing means to remove the impurities such as slag etc. When the metal melts a sample is taken out from this melt, poured in a testing die and the specimen is sent to lab for testing its chemical composition and hardness. The lab quickly calculates its hardness and checks its chemical composition by using SpectroMAX. If the melt have its composition and hardness within the permissible range, the melt is ready for pouring purpose, else, the element less or more then its permissible limit is balanced by adding other ingots. Gravity die casting is carried out in the foundry.
Why gravity die casting ? Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Die casting provides complex shapes within closer tolerances than many other mass production processes. Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant. Rollover die machines are used in foundry. 6 such dies are working here. 5 piece dies are used in these machines. The 5 pieces are the male part of the die and serves as a core. The dies are first pre heated. Skilled workers pour the melt in the dies. Then, machine automatically rollover. It takes approx. 3 min 30 sec in solidification of FIAT tractor pistons. Now, the pistons are heat treated as per company requirement through quenching followed by tempering. The pistons are first quenched in BBC machine, the temperature is maintained around 480C. Then, dipped in water, which is at 70C-100C. Then, tempered in FULMINA, here, the temperature is maintained around 180C. After, heat treatment 3-4 pistons are send to laboratory for testing there hardness. The runner and risers of the casting are then removed and the castings are ready to be dispatched to the machining area.
MACHINING:
The casted parts are then moved to machining area, several machining operations are performed here which gives pistons its required shape and finish. Four machining lines are there in machining department out of which three were currently working. One was making pistons for OEM, where as, other two were making pistons for open market.
Proof Turning
Seat Machining
Finish cavity
Taper
Grooving
Filling
Boring
Drilling
G. pin drilling
In machining area the manual lathes, automatic lathes, plc and drilling machines take part. The process flow is a U which utilizes the workers in there best way. Each worker at the same time works at two machines. The preferred process flow is not followed here, the actual process starts with making seats first, discussed below:
SEAT MACHINING:
Machining process starts from making the seat of the piston. Seat basically sets the reference for the preceding machining operations. Automatic lathe is used for this purpose and two tools take part in this operation. The machining time is approx. 18 sec here.
HEAD SHAPE:
Here also automatic lathe is used. Worker clamp the part w.r.t the seat made. Two tools take part in the operation. One tool removes the material from head giving it primary rough finish and specifying its length, where as, the second tool makes the rough cavity in the head. Cutting fluid is used here to reduce the friction and heat and to carry the chips away. The machining time is approx. 25sec here.
PROOF TURNING:
This step gives the piston its finished head (not the head cavity) and the rough surface to piston skirt. Three tools take part for the operation. Firstly two tools give rough finish to the piston skirt (two tools are used for this purpose because different diameters are required). Then, the third tool descends to give piston head (not the head cavity) its final finish. Cutting fluid is also used here. The machining time is approx. 39 sec here. After every 5-10 parts the worker checks for the accuracy. Dial indicator is used for this purpose. Firstly the dial indicator is set with the help of gauge for the desired length of the piston and then, after wards the dial indicator shows whether the piston is within the tolerance limit or not. OK parts are moved to get there head cavity finished.
COPY TURNING:
Automatic lathe machine with two diamond tip cutting tools gives piston skirt its super finish here. Worker just clamps the piston and the machine operating automatically super finishes piston skirt.
ACCURIZING:
It is the final step of whole machining operation. Here the bore is made accurate. First a rough finish then fine finish is achieved. After this process the bore finish is inspected using an air pressure gauge machine.
FINAL INSPECTION:
All the manufactured parts are then sent to piston inspection area for final and thorough inspection. Following parameters are checked and cleared in inspection area. LOCK TO LOCK DISTANCE. ROOT DIA (TOP COMPRESSION). ROOT DIA OIL. PIN SQUARENESS. BORE OFFSET. TOP COMPRESSION. CASTING DEFECTS. If any defect is seen then the piston is send back to the machining area or foundry, as per requirement. Around 300 400 diesel pistons are checked on daily basis. In case of over production to achieve the target max 700 diesel pistons can be inspected in one day.
RECOMMENDATIONS
COST EFFECTIVENESS:
Forged pistons should be manufactured instead of cast pistons. They are found very effective with respect to cost. Most of the companies globally are manufacturing forged pistons and saving cost now a days. Gas furnaces should be used instead of electric furnaces. They also can reduce the cost up to some extent. Traditional lathe machines should be replaced with CNCs as they are the one time cost. A single CNC can do the job of several lathes, with more efficiency and less cost. Fewer workers will b needed for them.
maintenance can solve the problem, after every 1015 castings the part should be checked for its dimensions, this will reveal the condition of die side by side and maintained before getting in to adverse conditions. In machining, the tools used were cheaper and not of such a good quality, good quality tools can give excellent results. The cutting fluid being used in the machining area is replaced when it comes to adverse conditions, it should be replaced periodically,.
MISCELLANEOUS:
Safety precautions were lacking in the plant. It should be made compulsory for the workers to at least wear the glasses, gloves and helmet, cap where applicable, as:
CONCLUSION:
Training at Atlas Engineering Ltd. is really a true learning experience. It has not only taught the utilization of bookish knowledge into practical field but also the ethics of professional life. This internship would remain the part of magnificence memories for the reason of AELs hospitability & efforts of my seniors to teach their activities. It is expected that this technical guidance & professional knowledge would be helpful in my future studies.