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Engine Parts Design

3 days MOT/COPIM-E
Level
Advanced
Audience
  • Engineers and technical staff involved in automotive or industrial engines design, who need to know the manufacturing processes (materials, casting, forge, machining, ...).
Purpose
  • To describe and explain metallurgy basics on ferrous and non ferrous alloys, processes of foundry, forge, machining, plastic material implementation, used in the manufacturing process of automotive engine parts.
  • To set up physical and economic conditions to choose manufacturing process.
Learning Objectives
  • To take into account the constraints related to the different manufacturing processes when designing engine parts: choosing the materials and the treatments, dimensional tolerances, surface roughness, shapes, clearance, assemblies, beading.
Prerequisite
  • IC engine fundamentals.
Ways and means
  • Interactive talks and illustrative videos.
  • Real components to be examined.
  • Real components to be examined, at different steps of the casting and manufacturing process.
  • Videos of the different processes.
Observation
This training adequately completes the training “Engine Design” (page 47).

Metallurgy 0.75 day
  • Structure, composition, mechanical characteristics (young's modulus, ductility, ...) and conditions of use of the alloy steels in the automotive industry: cast irons (gray iron (GI), ductile cast iron (dCI), quasiflake graphite cast iron (QGCI), steels, aluminum alloys.
  • Parts analysis modes.
  • Non destructive testing (penetrant inspection, ultrasonic, magnetic particle inspection, X-ray).
  • Choosing the materials for the engine main parts.
Forge 0.25 day
  • Hot forging principle and interest. Manufacturing process of a part. Tools design.
  • Drawing rules that take forging constraints into account.
  • Examples of forged components and adaptation to strength conditions: conrod.
  • Forged aluminum components: piston.
Foundry 1 day
  • Metal: from the liquid state to the solid state: shrinkage and soundness.
  • Design geometric imperatives of a casting.
  • Non permanent molds processes: green sand, chemically bonded sand, core making main processes.
  • Permanent molds processes: gravity die casting, low pressure die casting, die casting, and derived processes: squeeze casting, rheomolding.
  • Lost-wax pattern processes: lost wax, lost foam.
  • Design rules related to all the above processes.
  • Macro-economical criteria to choose the processes.
  • Examples of cast iron parts: cylinder-block, crankshaft.
  • Examples of cast aluminum: cylinder-block, piston.
Machining 0.5 day
  • Cutting parameters, basic operations and related tools: milling, drilling, boring, tapping.
  • Isostatisms, machining assemblies, routing methods, dimensioning and tolerancing.
  • Machining machines and related means: machining centers, special machines.
  • Examples of industrial issues: combustion chamber balancing, bore and camshaft line machining, intake and exhaust sides roughness.
  • Analysis of a cylinder head manufacturing line and a cylinder-block manufacturing line.
Plastics 0.5 day
  • Plastic manufacturing process and characteristics: polymerization, thermoplastics (characteristics, amorphous/crystalline structure, shrinkage), thermosetting, additives, damp effect, material sheets.
  • Plastics operating: injection, assembly techniques.
  • Design rules of plastic engine parts: stripping, drafts, sealing surface, ribs, welding, blowing. Prototyping techniques.