MANUFACTURING PROCESS FOR AN

ALUMINUM ALLOY PISTON

Group 5Eugene Oo

What is a piston?

Component of engines, reciprocating pumps, gas compressors and pneumatic cylinders.

Moving component 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

Components of a typical, four stroke cycle, DOHC piston engine. (E) Exhaust camshaft, (I) Intake camshaft, (S) Spark plug, (V) Valves, (P) Piston, (R)Connecting rod, (C) Crankshaft, (W) Water jacket for coolant flow.

http://www.animatedpiston.com/BMW.htm

So how and what?

Function- Piston Objective- Minimize Cost(priority) +

Maximize Safety Constraints- Al Alloy, 0.8-1kg,4-6mm,3D,

0.5mm, 5um, 1000 or 10000 pieces Variable- Shaping process

For Al alloy

0.8-1kg

4-6mm

3D

0.5mm

5um

1000 or 10000 pieces

What is Left?

Investment Casting -1000 Forging -Both Powder Methods -10,000 Conventional Machining -Both

COSTS $$$

Cost Comparison

Between the 3

Thank You