29-08-2014, 10:38 AM
I am submitting my six month industrial training report which i have done from Swaraj Engine Limited, Phase 9, Mohali during my training i have gained knowledge about different tractor engine assembly processes and methods. I had done a project on bumping (Bumping is a process in which T.D.C. of engine cylinder or clearance between piston and cylinder head is set by placing shims between liner and cylinder head) which is used to provide clearance between piston and cylinder head.
PROJECT Step 1 : To Study Bumping in Engine Theory: Bumping is a process in which T.D.C. of engine cylinder or clearance between piston and cylinder head is set by placing shims between liner and cylinder head. Why Bumping is used: Bumping is used to provide proper clearance between Piston and cylinder head. Generally piston comes above or below the T.D.C. of engine while rotation of crank shaft during assembly and when this happens it means it will result in head noise. In order to avoid this shims according to need, of desired thickness are introduced between liner and cylinder head. By this process all cylinders of engine have the same clearance value. • To maintain required compressed volume of Air • To avoid Piston touching Cylinder Head, which results in damage and head noise. • For better performance of engine Tools and Gauges used in BUMPING: BUMPING TOOL- It is in the form of a rectangular bar which is placed over liners with the help of studs and pressed with help of runners so that liner should be properly fitted during the movement of piston. BUMPING GAUGE- It measures the distance that how much piston is above or below the engine T.D.C. during its upward stroke and displays the reading on its digital panel when piston moves above the T.D.C. Shims are the spacer of big size which is inserted between liners and cylinder head in order to lift the cylinder head to avoid head noise. The table for proper shim thickness is shown below: READING Thickness of shim For positive reading 1.2mm 0 to -0.10 1.2mm -0.10 to-0.20 1.2mm -0.20 to-0.30 1.3mm -0.30 to-0.40 1.4mm -0.40 to-0.50 1.5mm Step 2: Identification and Observation of Problem Problem: Before shims are inserted on liners, oil is applied on shims in order to prevent rusting. Then these shims are placed on a inclined rod. In this arrangement shims get stick to each other. When they are inserted on liners then sometimes worker put two shims instead of one. This results in rejection of engine during testing. The naming of positions of different shims on stand was also not done properly Step 3: Finding a Solution Solution: 1.We have made a new arrangement of shims in which stand is not inclined, it becomes vertical and rods becomes long and horizontal and a stopper is fixed at the free end of rod. The naming of positions of different shims on stand is done properly. 2.We have used a pressure gun in order to apply air pressure on shims arrangement on horizontal stand so that their stickiness should not take place. By using these methods in arrangement of shims, the rejection of engine is decreased up to a great extent as shown in graph. Reading Shim Thickness -0.30 to-0.40 1.4mm -0.40 to-0.50 1.5mm
PROJECT Step 1 : To Study Bumping in Engine Theory: Bumping is a process in which T.D.C. of engine cylinder or clearance between piston and cylinder head is set by placing shims between liner and cylinder head. Why Bumping is used: Bumping is used to provide proper clearance between Piston and cylinder head. Generally piston comes above or below the T.D.C. of engine while rotation of crank shaft during assembly and when this happens it means it will result in head noise. In order to avoid this shims according to need, of desired thickness are introduced between liner and cylinder head. By this process all cylinders of engine have the same clearance value. • To maintain required compressed volume of Air • To avoid Piston touching Cylinder Head, which results in damage and head noise. • For better performance of engine Tools and Gauges used in BUMPING: BUMPING TOOL- It is in the form of a rectangular bar which is placed over liners with the help of studs and pressed with help of runners so that liner should be properly fitted during the movement of piston. BUMPING GAUGE- It measures the distance that how much piston is above or below the engine T.D.C. during its upward stroke and displays the reading on its digital panel when piston moves above the T.D.C. Shims are the spacer of big size which is inserted between liners and cylinder head in order to lift the cylinder head to avoid head noise. The table for proper shim thickness is shown below: READING Thickness of shim For positive reading 1.2mm 0 to -0.10 1.2mm -0.10 to-0.20 1.2mm -0.20 to-0.30 1.3mm -0.30 to-0.40 1.4mm -0.40 to-0.50 1.5mm Step 2: Identification and Observation of Problem Problem: Before shims are inserted on liners, oil is applied on shims in order to prevent rusting. Then these shims are placed on a inclined rod. In this arrangement shims get stick to each other. When they are inserted on liners then sometimes worker put two shims instead of one. This results in rejection of engine during testing. The naming of positions of different shims on stand was also not done properly Step 3: Finding a Solution Solution: 1.We have made a new arrangement of shims in which stand is not inclined, it becomes vertical and rods becomes long and horizontal and a stopper is fixed at the free end of rod. The naming of positions of different shims on stand is done properly. 2.We have used a pressure gun in order to apply air pressure on shims arrangement on horizontal stand so that their stickiness should not take place. By using these methods in arrangement of shims, the rejection of engine is decreased up to a great extent as shown in graph. Reading Shim Thickness -0.30 to-0.40 1.4mm -0.40 to-0.50 1.5mm