work shp training
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About The Company:
In The Last Summer, I Choose To Do My Summer Practice, So I Did It In
Iqab Fraij & Partners Company, This Company Is Steel Specialist.
The Company Location Is In North Marka Amman Jordan , Also There
Were Two Sections In The Company, First One Was For Turning Steel Sheets To
Make Large Pipes, Where They Used Two Revolving Wheel To Turn The Sheets.
The Second One , Where I Did My Training, Was The Cylinder Liner
Section, There Were Only One Engineer And All The Others Were Workers, The
Engineer Position Was The Production Engineer And Actually He Is One From
The Owners Of The Company.
In This Part Of The Factory There Was Two Department, First One The
Oven Part, Where They Reused The Remained Material Again, The Other One
Was The Lathe Part.
In Lathe Part, There Was:
1-Two External Lathing Machines.
2-Two Internal Lathing Machines.
3-3CNC Lathing Machines.
4-One Machine To Cut The Material By Lathing.
5-One Milling Machine.
6-One Grinding Machine.
What Is Cylinder Liner?
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Figure 1 : Cylinder Liner(Sleeve) & Piston & Piston Rings
Cylinder Liner Or Cylinder Sleeve Is A Cylindrical Part Made To
Be Fit In The Engine To Form The Cylinder & It Is One Of The Most
Necessary Parts To Make Up The Interior Of The Engine, ActuallyEach Engine Has Its Own Cylinder Liner Dimensions.
Function Of Cylinder Liner:
1-Formation Of Sliding Surface-:
Cylinder Sleeve Serving As An Inner Wall Of Cylinder ,
Forming A Sliding Surface For Piston Rings While Keeping The
Lubricant In, The Most Important Function Is The Excellent
Characteristic As Sliding Surface & These Four Important
Points:
a-High Anti-Galling Properties.
b-Less Wear On The Cylinder Liner It Self.
c-Less Wear On The Partner Piston Ring.
d-Less Consumption Of Lubricant.
1-Heat Transfer:
Figure 2 : Impact Inside Cylinder
Cylinder Liner Receives Consumption Heat Through Piston
& Piston Rings & Transmits The Heat To The Coolant.
2-Compression Gas Sealing:
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The Cylinder Liner Prevents The Compressed Gas And
Consumption Gas From Escaping Outside.
It Is Important That The Cylinder Sleeve Which Is Hard To
Transform By High Pressure & Temperature In The Cylinder.
The Cylinder Wall Is Under High Condition Of Pressure &Temperature ,With Piston & Piston Ring Sliding At High Speeds, So
In Particular ,Since Longer Service Life Required
For The Engines For Trucks And Busses , The Cast Iron Cylinder
Which Have Excellent Wear-Resistance Properties are Only Used ForCylinder Parts.
Also, For Lighter Engines, Material Shifting From Cast Iron To
Aluminum Alloys Are Used , But As The Sliding For The Inner
Cylinder, The Direct Sliding Motion Of Aluminum Alloys Has
Drawbacks In Deformation During Operation & Wear-Resistance. For
That Reason ; Cast Iron Used In The Most Cases.
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How To Make Cylinder Liner:
Cylinder Liner Usually Made From Cast Iron, Cast Iron Have A
Good Properties Such As Hardness & Thermal Conductivity ,
Expansion Coefficient & Has Excellent Wear Resistance.
Table 1 : Hardness For Some Materials
Table 2 : Expansion Coefficient & Thermal Conductivity
To Make A Cylinder Liner There Are Many Steps In Two
Sections, Oven Section & Lathe Section.
In Oven Section, They Melt The Remain Cast Iron From
Last Operation, In Order To Reuse It Again, They Use AnElectrical Oven, By The Way We Know That When We Melt
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The Material, It Loses Some Of Its Properties, So In Order To
Solve This Issue They Add Some Other Materials, Such As :
Si (Silicon) ,C (Carbon) ,Mg (Magnesium) ,C (Chromium) ,
The Temperature In Side The Oven Is 14500c & The Oven
Consumes 250 Kw/H.
Figure 3: Spoiled Cylinder
After That & While The Compound Is At Liquid StateThey Reshape It To The Cylinder Form. Then Leave It For
Cooling.
The They Move It To The Other Section, The Lathe
Section.
In This Section There Are Many Steps,(The Steps Are In
Order(
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1-External Lathing:They Put The Spoiled Cylinder
There, And Stare The Lathing, Because The Spoiled
Cylinder Has Very Bad Surface, Here They Made A
Step To Reshape It, In The Factory There Was Two
External Lathing Machines.
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2-Internal Lathing: Internal Lathing Is To Get Better
Surface Than The Spoiled One. There Was Two
Internal Lathing Machines.
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3-CNC Lathe: CNC Machine Is Always The Most
Accurate Machine, And Because The Cylinder Liner Is
Important Part In The Engine, It Has To Be Built In
Very Accurate Tolerances, So They Are Using TheCNC Machines, There Were Three CNC Machines
There But Unfortunately Only One Was Working.
Figure 5: CNC Machine
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The Cylinders To The Grinding Machine To Obtain
The Geometry Of The Parts.
Figure 6: Grinding Machine
5-Honing Machine: They Use This Machine To ObtainThe Inside Surface Of The Cylinder As Smooth, It
Take 1mm From The Inside Thickness.
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Figure 7 : Honing
Figure 8: Before CNC Machine
Conclusion:In That Period, I Have Been Saw The Lathing & Grinding Processes,
And If I Add What I Saw To What I Have Learned In Manufacturing
210, So Now I Have A Nice Vision About These Processes.
Also, Now I Know How To Make One Of The Most Important Function
In The Engines, Also I Become Familiar With Some New Advices
That I Have Never Hear About It Before, Such As
Micrometer(Micrometer Screw Gauge) & The Depth One, Also I
Learned How To Use Them.
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Figure 9 : Micrometer & Depth Micrometer
AppendixFigure 1 : Cylinder Liner(Sleeve) & Piston &
Piston Rings : Page 1
Figure 2 : Impact Inside Cylinder : Page 2
Table 1 : Hardness For Some Materials : Page 4
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Table 2 : Expansion Coefficient & Thermal
Conductivity : Page 4
Figure 3: Spoiled Cylinder : Page 5
Figure 4: External Lathe Machine : Page 6
Figure 5: CNC Machine : Page 7
Figure 6: Grinding Machine : Page 7
Figure 7 : Honing : Page 8
Figure 8: Before CNC Machine : Page 8
Figure 9 : Micrometer & Depth Micrometer :
Page 9
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