Engine Parts Design

Materials and Manufacturing Processes

MOT/COPIM-E

Who should attend?

  • This course provides a deeper knowledge and competencies on 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.
  • It helps setting up physical and economic conditions in order to choose a manufacturing process.
Audience :
  • Engineers and technical staff involved in automotive or industrial engines design, who need to know the manufacturing processes (materials, casting, forge, machining, …).

Level : Advanced

Course Content

  • Metallurgy

      • 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

      • 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

      • 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

      • 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

      • 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.

Learning Objectives

  • Upon completion of the course, participants will be able to:
  • take into account the constraints related to the different manufacturing processes when designing engine parts,
  • choose the materials and the treatments, dimensional tolerances, surface roughness, shapes, clearance, assemblies, beading needed.

Ways & 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.