Warranty Scrap Reduction in Single Cylinder Side Valve Engine

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Mechanical Final year Project in " Warranty Scrap in Single Cylinder Side Valve Engine". I did this as my Final year main project. It is an valuable project in the fabrication side, i got 200/200 marks for this project

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SUN COLLEGE OF ENGINEERING AND TECHNOLOGY Sun Nagar, Erachakulam UNDER :

SUN COLLEGE OF ENGINEERING AND TECHNOLOGY Sun Nagar, Erachakulam UNDER Anna university, Chennai April 2012

WARRANTY SCRAP REDUCTION IN SINGLE CYLINDER SIDE VALVE ENGINE :

WARRANTY SCRAP REDUCTION IN SINGLE CYLINDER SIDE VALVE ENGINE

WARRANTY SCRAP REDUCTION IN SINGLE CYLINDER SIDE VALVE ENGINE :

WARRANTY SCRAP REDUCTION IN SINGLE CYLINDER SIDE VALVE ENGINE Submitted by, LAKSHMANAN.U 97208114028 MANOJ KUMAR.G 97208114030 VIVEKANAND.C 97208114065 Guided by, Mr. R.S. JAYARAM M.E, (MBA) Asst. Professor

ABSTRACT:

ABSTRACT By analysis, we found that the high cost rejection component is CRANKCASE ASSEMBLY. F urther in depth analysis with failed component through field concerns, it is found at Valve areas. The failure area is abnormal wear in both inlet and exhaust valve guides, due to improper lubrication.

IMPORTANCE OF THE PROJECT:

IMPORTANCE OF THE PROJECT We have chosen MK20 engine for our side valve engine technique. It have severe drawbacks, as it locating the hot exhaust port immediately next to the cylinder. It has long burn times, larger combustion chamber surface area, and higher pollution outcome, etc. Many of these factors combine to cause inherently high emission levels, (particularly - HCs, NO X ), high fuel consumption and high engine noise.

AIM OF THE PROJECT:

AIM OF THE PROJECT By utilizing the benefits of side valve engine to achieve the power and green emission norms. A s of reducing the warranty rejection of crank case assembly into value reengineering & productive range. S ubsequently save the warranty scrap in terms of reusable through cost effective method.

ENGINE SPECIFICATION:

ENGINE SPECIFICATION TERMS SPECIFICATIONS MODEL MK 20 TYPE 4 Stroke, Single Cylinder, side valve Engine Fuel (Starting Fuel) Kerosene (Petrol) Bore x Stroke (mm) 68 x 53 Total Displacement (CC) 192 Max. Power (HP) 3.4 @ 3600rpm Compression Ratio 4.8 : 1 Ignition System Transistor System Lubrication System Forced Splashing

ENGINE NOMENCLATURE:

ENGINE NOMENCLATURE The piston slides up and down in the cylinder bore and is linked to the crankshaft by means of a connecting rod . They require two up-and-down strokes of the piston to complete one cycle of operation . The power stroke converts chemical energy into mechanical motion by burning the gasoline’s hydrogen and carbon mixed with the air’s oxygen.

DEFINING THE CRANK CASE:

DEFINING THE CRANK CASE Crank case is cast integral with the cylinder block made of Aluminum alloys. It supports crankshaft and camshaft with the help of bearings. Crank case takes the high cost efficient part in the engine.

CRANKCASE SIDE VIEW:

CRANKCASE SIDE VIEW

% CONTRIBUTION TO ENGINE COST:

% CONTRIBUTION TO ENGINE COST

ROOT CAUSE FOR PROBLEM:

ROOT CAUSE FOR PROBLEM Valve guide wear is the root cause for the crankcase warranty failure problem, due to longer burn times. The primary symptom of valve failure is loss of compression. When the wear absorbed, crank case must be replaced, which is totally high cost reduction.

VALVE GUIDE FAILURE: POSSIBLE CAUSES:

VALVE GUIDE FAILURE: POSSIBLE CAUSES Improper Valve Guide material. Wrong fit-tolerance between Valve guides – Valve stem. Manufacturing variation of valve guide and valve components. Wrong / Less / No lube oil usage.

DIAGRAM SPECIFICATION:

DIAGRAM SPECIFICATION Engine – Top view Valves

BREAK DOWN REPORT BY CUSTOMER:

BREAK DOWN REPORT BY CUSTOMER

FALIURE MODEL:

FALIURE MODEL This is the failure model of the crank case assembly. In the past days the crank case is to be replaced fully, now both the valve guides replacement is enough. By this criteria, the cost will be saved.

CRANKCASE ASSEMBLY WITH VALVE GUIDE :

CRANKCASE ASSEMBLY WITH VALVE GUIDE VALVE GUIDE IN POSITION VALVE GUIDE PULLED

DETAILS ABOUT VALVE GUIDE:

DETAILS ABOUT VALVE GUIDE Inlet valve guide is made of Brass, and outlet valve guide is of Copper. As exhaust gas temperature is high, copper of melting point 1083°c, while brass has 940°c. Inlet valve seat = ø33.00/33.025mm Outlet valve seat = ø32.00/32.025mm Valves guide hole = ø10.00/10.018mm

VALVE GUIDE SEATING ARRANGEMENT TECHNIQUE:

VALVE GUIDE SEATING ARRANGEMENT TECHNIQUE Remove the cylinder head from the vehicle to a safe working area & clean the parts. Both the valves are shrink in Liquid Nitrogen at Sub-Zero degree temperature, which provide leak proof. Insert the valve into the guide, allowing the valve to remain off of its seat.

VALVE GUIDE CHECKING DEVICES:

VALVE GUIDE CHECKING DEVICES Dial indicator is used to check the amount of valve guide wear. Small hole gauge is used to check the inner diameter of the valve guide. Micrometer is used to measure the valve stem.

VALVE GUIDE SERVICING:

VALVE GUIDE SERVICING When servicing valve guides, remember that the  guides  must  be  clean  and  in  good  condition for  normal  valve  seating. If, after  cleaning  a  valve guide, you find it worn, remove  it  and  install  a new one. To remove old or worn valve guides and install new ones, you need special guide removing and replacing tools.

VALVE NOMENCLATURE:

VALVE NOMENCLATURE

IMPLEMENTATION OF SOLUTION:

IMPLEMENTATION OF SOLUTION The puller for the Valve Guide was produced with the help of production Engineering department. VALVE GUIDE PULLER CAD MODEL

CAD MODEL VALVE GUIDE PULLER ASSEMBLY:

CAD MODEL VALVE GUIDE PULLER ASSEMBLY

VERIFICATION:

VERIFICATION COST COMPARISON BEFORE IMPROVEMENT Crankcase warranty average (month) = 8 Crankcase cost = 2250 INR Total warranty cost = 6750 INR AFTER IMPROVEMENT Crankcase warranty average (month) = 8 Valve Guide cost = 45 INR (Including inlet and exhaust valve) Total Warranty cost = 135 INR

CONCLUSION:

CONCLUSION An engine manufacturing company has receiving ‘n’ number of warranty claims from customers, who consumed the products within the warranty period offered by company to compete its competitors in the product range. And thus our project to increase the life of the Engine and increasing the warranty period by necessary changes in the area.

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