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    Detailed Project Report on Automotive Engine Valves

    Detailed Project Report on Automotive Engine Valves
    Detailed Project Report on Automotive Engine Valves
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      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)


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