Internship Report Atlas Engineering

“In the name of ALLAH the most Compassionate, the most Merciful.”

Feel free to contact for any queries & constructive feed back: [email protected]

INTERNSHIP REPORT(10/12/2010 – 03/01/2011)

Submitted By:

Muhammad Ali KhalidMuhammad Hammad KhanMuhammad Shoaib Idrees

2nd year student (Bachelors of Engineering)Department of Industrial & Manufacturing Eng.Ned University of Engineering & Technology


DEDICATION

We want to dedicate this projectto our parents, and all our

friendsfor being with us and helping usin each and every difficulty wefaced in this project completion

and to our teachers and allthose who taught us, trained us

and polished our abilities atAtlas Engineering Ltd.


ACKNOWLEDGEMENT

All praise unto Almighty ALLAH, the Lord of all worlds, who endowed us with the ability to complete successfully this period as internee, Though we

did not conceal our self capable to do so

“Our Lord, we have never been unblessed in our prayer to you.”

We are thankful to Mr. Javed Iraqi (GM - HR) for providing us this great opportunity of doing internship at Atlas Engineering Ltd. We are highly obliged for the kindness and great cooperation provided by Staff of the Atlas Engineering Ltd.

We are extremely thankful for the cooperation and help provided by: Mr. Junaid Ahmed Siddiqui (Manager Al dept.), Engr. Muhammad Umair (Engineer machining dept.), Engr. Waseem (Foundry Engineer), Mr. Khwaja (Assistant manager Al dept.) and Mr. Qamar (Supervisor Al-foundry) for spending their valuable time and responding to our queries and giving us an insight of how an organization runs, what are the important principles of a working environment.

We would also like to thanks Mr. Syed Adeel Ahmed Bukhari (HR coordinator) for guiding us throughout the project. And last but not the least, we are also thankful to all those personnel’s who always have sincere feelings and guided us at their best.


Group members Muhammad Ali Khalid

Muhammad Hammad KhanMuhammad Shoaib Idrees

INTRODUCTION OF THE COMPANY

ATLAS GROUP:

The foundation of the Atlas Group was laid in 1962 with the establishment of Shirazi Investments (Pvt) Limited with a capital of half a million rupees and three men doing business in trading shares and real estate. Today Atlas is a diversified group dealing in engineering, power generation, financial services and trading. It consists of seven public limited companies out of which five are quoted on the Stock Exchanges in Pakistan, and six private limited companies. Atlas shareholders equity now stands over 25 billion rupees; assets have increased to over 65 billion rupees; personnel strength is over 7000 and annual sales have crossed 70 billion rupees. The Group strategic direction is determined by the Group Executive Committee while each company functions autonomously within the framework of the predetermined policy.

YUSUF H. SHIRAZI (Chairman)


Fig 1: Growth at a Glance (Atlas Group)

Atlas group operates in three sectors:

1- Engineering Sector2- Trading Sector3- Financial Sector

1- ENGINEERING SECTOR: The engineering sector includes the following listed companies

1- Atlas Honda Limited

2- Honda Atlas Cars (Pakistan) Limited

3- Atlas Engineering

4- Atlas Battery Limited

5- Atlas Power

2- TRADING SECTOR:

The trading sector includes the following listed companies


1- Shirazi Trading Co. (Pvt.) Limited

2- Honda Atlas Power Product (Pvt.) Limited

3- Total Atlas Lubricant Pakistan (Pvt.) Limited

3- FINANCIAL SECTOR:

Atlas Group has following three financial companies

1- Muslim Insurance Company Limited

2- Atlas Investment Bank Limited

3- Atlas Asset Management Co. Limited

ATLAS ENGINEERING:

Atlas Engineering Limited (formerly Allwin Engineering Industries Limited) was established in 1951 as a partnership firm. It became a private limited company in 1964, and a public limited company in 1967. The control of the company was acquired by the Atlas Group in 1981. At present, Atlas Engineering is one of the largest and oldest manufacturers of automotive parts and components in the private sector in Pakistan. Atlas Engineering has state-of-the-art facilities to produce Cast Iron process pig iron and aluminum alloys through various stages into high precision automotive components and has full access to technical know-how and back-up of world renowned manufacturers like the Shindengen Japan, F.C.C. Co. and Honda Foundry Japan. The Company manufactures diesel pistons, piston pins, cylinder liners/sleeves, motorcycle pistons, cylinders, CDI & Regulator, Pressure Die Casting, Aluminum Components, radiator assemblies and radiator cores and a host of fully-machined cast iron parts (both grey and ductile). These include brake drums, brake discs, flywheels and other high quality precision engineered components for all manufacturers of cars, light commercial vehicles, trucks, buses and tractors including Millat's Massey Ferguson and Al-Ghazi's Fiat Tractors, besides Honda, Suzuki, Toyota, Daihatsu and


Hyundai cars, Nissan , Hino, Mazda, Dong Feng trucks & buses and Honda and Yamaha motorcycles. Atlas Engineering products are comparable with those of any international manufacturer and as such are also exported wherever demanded. Various assemblers have given excellence awards to Atlas Engineering for achievements in quality and delivery. The facilities at Atlas Engineering have been extended and modernized steadily over the last decade, and are amongst the best in the engineering sector of the country. As old machines are phased out, new machines including CNCs, and semiautomatic machining lines are being added. Further expansion of facilities for manufacture of piston and allied products pressure die casting and cast iron parts is being undertaken. The production facilities are backed by well-equipped quality assurance system, design and applied research facilities. Atlas Engineering policy and operations are guided by the management approach of Atlas Group, Organization development through self development.

LOCATION & AREA:

Location Atlas Engineering is situated at 15th mile, National Highway, Landhi, Karachi –75120Pakistan.

Land 83,651sq.m.Built-up (covered) area 31,217sq.m.

FACILITIES:

1- Melting (Cast Iron, Aluminum)2- Casting (Cast Iron, Aluminum)3- Machining (Cast Iron, Aluminum)4- Assembly (Radiator, CDI + Regulator)5- Quality Assurance6- Logistics7- Information Technology

LAB & OTHER FACILITIES:

CAD, applied research facilities, coordinate measuring machine (CMM), Spectrometer standards room, chemical and metallurgical laboratories with which the company has built up a reputation for quality


and reliability of supply. The company manufactures components for all leading manufacturers of the country as well as for the replacement parts market where its products compete favorably with established imported brands. Recognition of human resource as a key resource guides the company policy and operations. With emphasis on training and self-development the company is making strides towards creating a center of excellence. Staff are sent to prestigious certification of Pakistan for training and development. Further more continued education of staff is encouraged at higher level.

THE INTERNSHIP

Aluminum products department was our department of interest. An introductory visit started our internship. Diesel piston was made our product of study. Objective was to completely study the process followed by Atlas Engineering Limited in manufacturing diesel pistons and to give sound recommendations to improve the process with respect to cost effectiveness, production rate increment and control over rejection.

THE PLANT

Aluminum Products Plant at Atlas Engineering Limited is the purpose build plant which fulfils the needs of the company. Workers working in plant are very skilled persons; they show their devotion to work. Numerous quality products are manufactured here, including precision engine and body parts and pistons for diesel as well as petrol engine, pressure die components and other Aluminum components.


Atlas Honda LimitedPISTON:Piston CD-70Piston CG-125Piston KCC-100Piston KTA

DIE CASTING PARTS:Hub rear CD-70Hub front CD-70Panel rear CD-70Panel front CD-70

OTHER ALUMINUM PARTS:Holder handle pipe KCC-100Holder A-1 up KCC-100Metal upper CG-125 HondaMetal bottom CD-70 HondaHolder A-1 upper commonHolder B-1 under CD-70Front metal comp upper KTAAJoint metal comp upper KTTAUpper holder KTAABridge fork top KTAA

Millat TractorsPiston, MF240

Al Ghazi TractorsPiston FIAT

Piston (commercial market)HinoMazdaMF – 240/135/375FIAT – 32/38Bedford – 330Ford T/VanBelarusFord tractor 3600/3610/4000/4600

Other PartsBracket upper (L) YamahaCrown handle Yamaha motorcycle


PISTON – BREIF OVERVIEW

The piston can be called the “heart” of an automobile engine. Pistons play a central role in powering a car by means of its pumping motion within the cylinders. Metal rings are encircled on piston which with oil lubrication eliminates friction between cylinder wall and piston. Pistons are normally round or slightly elliptical. The piston crown (top) can be flat or roughly convex or have some cavity on it. A rod connects the piston to a crank shaft which turns the gears and powers the drive train.

Fig 2: Piston – brief overview

THE PROCESS


FLOW CHART:

RAW MATERIAL

TESTING & STORAGE

CASTING REJECTION

MACHINING REJECTION

FINAL INSPECTION

STORAGE & DELIVERY

The process followed by Atlas Engineering Ltd for making pistons has a logical flow i.e. the forward flow. Raw materials enter from one side of the plant and complete pistons are delivered form the other side, only the scrap has the opposite flow.

RAW MATERIAL:

Mainly Aluminum is used for manufacturing pistons, where as, little quantities of other elements such as Silicon, Magnesium, and Iron also take part in piston manufacturing.

VIRGIN INGOTS: Company purchases virgin ingots from different dealers. Since our project is related to diesel pistons so we will discus the composition of ingots purchased for diesel pistons. Mainly two types of ingots are purchased for diesel piston, namely, LM-13 & LM-28. LM-13 are purchased from SUN METAL (local dealer) and LM-28 imported from LUCKY ALLOY (Dubai). A single bundle contains up to 108 virgin ingots, weighs approx. 700 kg.


Our piston of interest is of FIAT tractor, LM-28 type of ingots is used for manufacturing these pistons. Composition is shown below:

Elements Si %

Fe %

Cu %

Mn %

Mg %

Cr %

Ni %

Zn %

Ti %

Ca %

CompositionRange

17.0019.00

0.000.60

1.301.80

0.000.30

1.001.30

0.000.60

0.801.30

0.000.20

0.000.20

0.0010

Elements Cd %

Co %

Na ppm

P ppm

Pb %

Sn %

Al %

CompositionRange

0.0019 0.000.50

11.17 80.00120.0

0.000.15

0.000.15

78.7

SWARF INGOTS: Swarf ingots are those ingots which are made by atlas itself from

the chips which are removed from the piston in the machining operation and the slag and residue left in the furnaces. In these, usually the composition of magnesium decrease from the permissible limit, to over come this problem, few ingots of magnesium are also added along with swarf ingots.

TESTING & STORAGE:

Atlas Engineering Ltd. has its own lab, equipped with numerous machines related to material testing, such as, SpectroMAX, Brinnel & Rockwell hardness testing machines etc. The ingots purchased from dealers are first checked for there composition. One ingot is taken out from each bundle and sent to lab to check for its composition, SpectroMAX is used for this purpose. Hardness is also tested in the lab, if the ingot is found to be in the permissible limit of the composition and hardness, then it is stored in the stores and issued MIR (material issuing requisite).


CASTING:

In foundry, the casting starts from melting the ingots. Five electric furnaces are there in foundry for diesel pistons, out of

which four were currently working for diesel pistons, where as, one was busy for child parts (due to there high demand).

Furnaces have the capacity of max. 500 kg. Virgin ingots along with swarf ingots, runner, risers and magnesium

ingots as per requirement are melted in the furnace. It takes around 1.5–2 hours in melting and degassing both. Degassing means to remove the impurities such as slag etc. When the metal melts a sample is taken out from this melt, poured in

a testing die and the specimen is sent to lab for testing its chemical composition and hardness.

The lab quickly calculates its hardness and checks its chemical composition by using SpectroMAX.

If the melt have its composition and hardness within the permissible range, the melt is ready for pouring purpose, else, the element less or more then its permissible limit is balanced by adding other ingots.

Gravity die casting is carried out in the foundry.Why gravity die casting ? Die casting is an efficient, economical process offering a broader range of shapes and components than any other manufacturing technique. Die casting provides complex shapes within closer tolerances than many other mass production processes. Die casting produces parts that are durable and dimensionally stable, while maintaining close tolerances. They are also heat resistant.

Rollover die machines are used in foundry. 6 such dies are working here. 5 piece dies are used in these machines. The 5 pieces are the male part of the die and serves as a core. The dies are first pre heated. Skilled workers pour the melt in the dies. Then, machine automatically rollover. It takes approx. 3 min 30 sec in solidification of FIAT tractor pistons.


Now, the pistons are heat treated as per company requirement through quenching followed by tempering.

The pistons are first quenched in BBC machine, the temperature is maintained around 480ºC.

Then, dipped in water, which is at 70ºC-100ºC. Then, tempered in FULMINA, here, the temperature is maintained

around 180ºC. After, heat treatment 3-4 pistons are send to laboratory for testing

there hardness. The runner and risers of the casting are then removed and the castings

are ready to be dispatched to the machining area.

MACHINING:

The casted parts are then moved to machining area, several machining operations are performed here which gives pistons its required shape and finish. Four machining lines are there in machining department out of which three were currently working. One was making pistons for OEM, where as, other two were making pistons for open market.

PROCESS FLOW FOR DIESEL PISTONS (FIAT):

Casting received formAl – foundry

Proof Seat Finish face & Finish Taper Turning Machining rough dia cavity


Grooving

Lock Copy G. pinFilling Accurizing Grooving turning Boring Drilling drilling

Piston final inspection

In machining area the manual lathes, automatic lathes, plc and drilling machines take part. The process flow is a “U” which utilizes the workers in there best way. Each worker at the same time works at two machines. The preferred process flow is not followed here, the actual process starts with making seats first, discussed below:

SEAT MACHINING: Machining process starts from making the seat of the piston. Seat basically sets the reference for the preceding machining operations. Automatic lathe is used for this purpose and two tools take part in this operation. The machining time is approx. 18 sec here.

HEAD SHAPE: Here also automatic lathe is used. Worker clamp the part w.r.t the seat made. Two tools take part in the operation. One tool removes the material from head giving it primary rough finish and specifying its length, where as, the second tool makes the rough cavity in the head. Cutting fluid is


used here to reduce the friction and heat and to carry the chips away. The machining time is approx. 25sec here.

PROOF TURNING: This step gives the piston its finished head (not the head cavity) and the rough surface to piston skirt. Three tools take part for the operation. Firstly two tools give rough finish to the piston skirt (two tools are used for this purpose because different diameters are required). Then, the third tool descends to give piston head (not the head cavity) its final finish. Cutting fluid is also used here. The machining time is approx. 39 sec here. After every 5-10 parts the worker checks for the accuracy. Dial indicator is used for this purpose. Firstly the dial indicator is set with the help of gauge for the desired length of the piston and then, after wards the dial indicator shows whether the piston is within the tolerance limit or not. OK parts are moved to get there head cavity finished.

FINISH HEAD SHAPE: Manual lathe machine is used here for giving the head cavity its super finish. Skilled worker makes it easily. No cutting fluid used.

TAPER OIL HOLE: Automatic drilling machine is used here to drill the taper holes. Worker clamp the piston with respect to the seat made and machine automatically drills 4 holes. These holes allow oil to get inside the piston.

BOSS OIL HOLE: Manual drilling machine is used here to drill the boss oil holes.Skilled worker drills total 4 holes in the piston, these holes allow oil to get inside the piston and reduce friction with the pin attached.

DIA & GROOVING: Automatic lathe machine is used here to give piston skirt finer finish and to make the groves on it. The worker clamps the piston with respect to the seat made and then the lathe automatically with the help of 4 cutting tools finer finishes the skirt and then 7 tools work for making the groves on it. Cutting fluid is also used here. After 5-10 parts the worker checks for the accuracy. Dial indicator is used for this purpose.


COPY TURNING: Automatic lathe machine with two diamond tip cutting tools gives piston skirt its super finish here. Worker just clamps the piston and the machine operating automatically super finishes piston skirt.

GUDGEON PIN BORING: Here also automatic lathe machine is used. The operation takes place in two steps here. Firstly, the first tool gives rough finish then the second one gives it the required super finish.

BOSS RADIUS & LOCK GROOVING: In this process bore is chamfered and lock is produced in the bore. This process is done in two steps. First a piston is fixed on machine and the bore is chamfered and then that chamfered piston is placed on next slot where the lock is produced while a new piston is fixed on the chamfering slot. Both operations are done at the same time.

ACCURIZING: It is the final step of whole machining operation. Here the bore is made accurate. First a rough finish then fine finish is achieved. After this process the bore finish is inspected using an air pressure gauge machine.

FINAL INSPECTION:

All the manufactured parts are then sent to piston inspection area for final and thorough inspection. Following parameters are checked and cleared in inspection area.

LOCK TO LOCK DISTANCE.

ROOT DIA (TOP COMPRESSION).

ROOT DIA OIL.

PIN SQUARENESS.

BORE OFFSET.


TOP COMPRESSION.

CASTING DEFECTS.

If any defect is seen then the piston is send back to the machining area or foundry, as per requirement. Around 300 – 400 diesel pistons are checked on daily basis. In case of over production to achieve the target max 700 diesel pistons can be inspected in one day.

STORAGE & DELIVERY:

The pistons are now ready to be used. They are stored in the well managed store room and delivered to OEM’s and to the market as per requirement.

RECOMMENDATIONS

COST EFFECTIVENESS:

Forged pistons should be manufactured instead of cast pistons. They are found very effective with respect to cost. Most of the companies globally are manufacturing forged pistons and saving cost now a days.

Gas furnaces should be used instead of electric furnaces. They also can reduce the cost up to some extent.

Traditional lathe machines should be replaced with CNCs as they are the one time cost. A single CNC can do the job of several lathes, with more efficiency and less cost. Fewer workers will b needed for them.

PRODUCTION RATE INCREMENT:


Forged pistons here also take the advantage, there manufacturing time is much less than the cast one, as there is no melting, degassing, quenching, tempering required, and not so many machining processes.

Automatic die casting machines can increase the production rate. Manually, to set up the dies (cores) it take a long time while in automatic die machines it will be faster, manual dies for diesel pistons can be compared with the automatic machines for petrol piston, they are quite faster.

CNCs can reduce the machining time to great extent, as a single machine will be doing several operations in less time with more efficiency.

CONTROL OVER REJECTION:

At present the dies are maintained only when the rejection come from machining area, and in mean while time plenty of more defected parts had been casted from the defected die. Periodic checking and maintenance can solve the problem, after every 10–15 castings the part should be checked for its dimensions, this will reveal the condition of die side by side and maintained before getting in to adverse conditions.

In machining, the tools used were cheaper and not of such a good quality, good quality tools can give excellent results.

The cutting fluid being used in the machining area is replaced when it comes to adverse conditions, it should be replaced periodically,.

MISCELLANEOUS:

Safety precautions were lacking in the plant. It should be made compulsory for the workers to at least wear the glasses, gloves and helmet, cap where applicable, as:

“Quality makes no sense without U & I ” 2 shutdowns per year should be managed for complete maintenance of

the machines and every thing in the plant. Machines should be periodically oiled, it was not practically followed

in the plant. In a nut shell, 5S should be followed.


CONCLUSION:

Training at Atlas Engineering Ltd. is really a true learning experience. It has not only taught the utilization of bookish knowledge into practical field but also the ethics of professional life. This internship would remain the part of magnificence memories for the reason of AEL’s hospitability & efforts of my seniors to teach their activities. It is expected that this technical guidance & professional knowledge would be helpful in my future studies.


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Internship Report Atlas Engineering

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