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Engine Parts Design

Engine Parts Design

3 days

MOT/COPIM-E

Request an in-house session

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Who should attend?

Learning Objectives

Sessions

This course is not scheduled.

Who should attend?

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

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.

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.

Course Content

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.

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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.