Detailed Project Report on Automotive Engine Valves

AUTOMOTIVE ENGINE VALVES

[EIRI/EDPR/1120] J.C. 9766

INTRODUCTION

The inlet valve is used to allow the income charge into the engine during the suction stroke. Exhaust valve used to allow the exhaust gases out of the engine during exhaust stroke. Both the valves close the combustion chamber during the rest of the cycles. 

The valve movement is constrained by a valve guide. The seat inserts provide the seating surface for the valves to seal the combustion chamber. The opening and closing of the valves are controlled according to the valve timing by the camshaft, which gets drive from the crankshaft. 

The valve train components and the mechanical load for the inlet and exhaust valves remains similar whereas the operating environment of both the valves differ which make the design considerations different for inlet and exhaust valves. The inlet valve is always cooled by the incoming charge in the inlet port so it operates at a lesser temperature. The exhaust valve is always surrounded by the hot gases and hence operates at a high temperature. The design department considers the above functional requirements during the design of valves. 

The valves are manufactured through forging, Heat treatment and machining route. High precision dimensions like stem diameter, Seat height and seat Runout are maintained through the grinding process.

Poppet valves are used in most piston engines to open and close the intake and exhaust ports in the cylinder head. The valve is usually a flat disk of metal with a long rod known as the valve stem attached to one side.

The stem is used to push down on the valve and open it, with a spring generally used to return it to the closed position when the stem is not being depressed. At high revolutions per minute (RPM), the inertia of the spring makes it too slow to return the valve to its seat between cycles, leading to 'valve float'. In this situation desmodromic valves are used which, being closed by a positive mechanical action instead of by a spring, are able to cycle at the high speeds required in, for instance, motorcycle and auto racing engines.

The engine normally operates the valves by pushing on the stems with cams and cam followers. The shape and position of the cam determines the valve lift and when and how quickly (or slowly) the valve is opened. The cams are normally placed on a fixed camshaft which is then geared to the crankshaft, running at half crankshaft speed in a four-stroke engine. On high-performance engines, the camshaft is movable and the cams have a varying height, so by axially moving the camshaft in relation with the engine RPM, also the valve lift varies. 

COST ESTIMATION

Plant Capacity            50,000 Engine Valve/Day

Land & Building (2000 sq.mt.)    Rs. 2.09 Cr

Plant & Machinery                    Rs. 41.21 Lac

Working Capital for 3 Months    Rs. 14.00 Cr

Total Capital Investment          Rs. 16.79 Cr

Rate of Return                          99%

Break Even Point                      24%

CONTENTS

INTRODUCTION

VALVE POSITION

USES

B.I;S. SPECIFICATIONS

MARKET SURVEY

INDUSTRY SNAPSHOT

ORGANIZATION AND STRUCTURE

CURRENT CONDITIONS

AMERICA AND THE WORLD

RESEARCH AND TECHNOLOGY

SEGMENT TOTALS, RANKED BY FEB UNIT SALES

TOP 20 VEHICLES, CURRENT MONTH'S SALES

INTERNATIONAL DEVELOPMENTS AND TRADE

CHINA

JAPAN

SOUTH KOREA

MANUFACTURING PROCESS

MATERIAL SELECTION

VALVE

CRITERIA OF EXHAUST VALVE

STAINLESS STEELS ARE COMMONLY DIVIDED INTO FIVE GROUPS:

TABLE BELOW ARE THE PROPERTIES OF SAF 2507® (UNS S32750)

VALVE SEAT INSERT

CRITERIA FOR MATERIAL SELECTION OF ENGINE VALVE SEAT

INSERT

EXTRUSION

FRICTION WELDING

UPSETTING

FORGING

HEAT TREAMENT

STELLITE DEPOSITION

HEAD DIAMETER FACING

GROOVE CNC TURNING

TIP HARDENING

NECK PROFILE TURNING

SEAT GRINDING

SURFACE FINISHING

ALTERNATIVE PROCESS

ALTERNATIVE PROCESS

VALVE LENGTH CALCULATIONS

PRODUCTION

ONE-PIECE-FORGED VALVES

BIMETALLIC FORGED VALVES

HARD CHROME PLATE

TITANIUM VALVES:

SUPER ALLOY:

HOLLOW STEM VALVES:

COMPETITION PLUS SODIUM FILLED HOLLOW STEM VALVES

TITANIUM COMPETITION VALVES

MANUFACTURING PROCESS OF FLOW PROCESS CHART

PLANT LAYOUT

AUTOMOTIVE VALVES

STAINLESS STEEL RODS

CENTRELESS GRINDING MACHINE

DUPLEX GRINDER

AUTOMATIC LATHES

HEAT TREATMENT FURNACE

WASHING TANKS

BENCH GRINDER

BENCH DRILLING MACHINE

BRAZING EQUIPMENTS

CHAIN PULLEY

HARDNESS TESTING MACHINE

METALLURGICAL MICROSCAPIC MACHINE

ULTRASOUND MACHINE

MEASURING EQUIPMENT

D.G. SETS

ELECTRICAL POWER

UPSET MACHINES

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)