Machine Tools and

Metrology
Assignment

Submitted by:

Ben Mathews Tom

Dheen Hamza
Jafin Noushad
Sahal Rahman
Sreehari R
 Acknowledgement

We want to express our sincere gratitude to Dr. Anand Sekhar R, our faculty
mentor, whose knowledge and direction have been essential to the project's
successful completion. Throughout the fabrication process, their helpful
criticism and encouragement were crucial and their commitment to
mentoring and educating has substantially improved our comprehension of
the subject.

Our profound gratitude also goes out to the Machine Tools Lab Technical
Staff, whose help and encouragement were invaluable. We also want to
thank for the facilities and resources the Mechanical Engineering
Department supplied, which were crucial to the project's successful
completion. The fabrication procedure was made much easier by having
access to a workshop.

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 INDEX

Sl No Contents Page No

1 Introduction 4

2 Dimensioned Manufacturing Drawing 5

3 Tolerances and Material Specifications 6

4 Fabricated Product Image 8

5 Machining Process Involved 9

6 Cost Computation 15

7 Dimensional Inspection 16

8 Geometric Evaluation 18

9 Conclusion 19

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 Piston Pin

A piston pin, also known as a wrist pin, is a crucial component in an internal

combustion engine. It connects the piston to the connecting rod, allowing for the
transfer of force as the piston moves up and down within the cylinder.

Key Functions:
1. Connection: It serves as a pivot point for the connecting rod, enabling
the transfer of motion from the piston to the crankshaft.
2. Load Bearing: It handles significant forces during combustion and the
piston’s movement, requiring strong materials to withstand high stresses.
3. Alignment: Proper alignment is essential to minimize wear and ensure
smooth operation.

Types:
 Floating Pin: Moves freely within the piston and connects to the
connecting rod, allowing for easier assembly and disassembly.
 Fixed Pin: Permanently attached to either the piston or the connecting
rod, reducing the complexity of assembly but potentially increasing wear.

Materials:
Piston pins are usually made from high-strength steel or aluminium alloys to
balance weight and durability.

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 Tolerance and Material Specification of
Piston Pins (IS 11952:1986)

Tolerance Specifications:
Piston pins require precise tolerances to ensure proper fit and function within
the engine. Key tolerances include:

4. Diameter Tolerance:
Typical tolerances for piston pin diameters range from ±0.002 mm to ±0.01
mm, depending on the application and manufacturing processes.

2. Length Tolerance:
Length tolerances are often around ±0.01 mm to ±0.03 mm, ensuring that the
pin fits correctly between the piston and connecting rod.

5. Roundness and Straightness:

Roundness tolerances may be specified as less than 0.01 mm, while
straightness tolerances can also be within similar ranges to prevent binding
and ensure smooth operation.

6. Surface Finish:
The surface finish is typically specified in terms of Ra (roughness average),
often requiring values around 0.2 to 0.4 micrometres to minimize friction and
wear.

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Material Specifications
The materials used for piston pins must offer high strength, durability, and
resistance to wear and fatigue. Common material specifications include:

7. Steel Alloys:
Chromoly Steel (e.g., SAE 4130 or 4340): Offers excellent strength-to-weight
ratios, fatigue resistance, and wear properties.
Carburized Steel: Often used for its improved surface hardness and wear
resistance.

2. Aluminium Alloys:
Aluminium 7075 or 2618: Lightweight with good strength properties, often
used in high-performance applications where weight reduction is critical.

8. Coatings:
Piston pins may also be treated with surface coatings such as nitriding or hard
anodizing to enhance wear resistance and reduce friction.

9. Heat Treatment:
Heat treatments like quenching and tempering are often employed to improve
the strength and hardness of steel piston pins.

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8
 Machining Process Involved
Facing
Facing is a fundamental lathe operation used in the machining industry to
produce a flat surface perpendicular to the axis of rotation of a workpiece.
This operation is typically performed at the beginning or end of a machining
process to ensure that the workpiece has a smooth and accurate end face.

Aspects of Facing Operation

1. Purpose:
o Flat Surface Creation: The main goal is to produce a flat, smooth
surface on the end of a cylindrical workpiece.
o Squaring Off: It is often used to square off the ends of a part,
ensuring that subsequent machining operations can be performed
accurately.
o Surface Finish: Facing can improve the surface finish of a part,
making it suitable for aesthetic purposes or to meet specific
tolerances.
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2. Process:
o Setup: The workpiece is mounted securely on the lathe, typically
in the spindle.
o Tooling: A cutting tool is positioned perpendicular to the axis of
the workpiece.
o Cutting Motion: The lathe rotates the workpiece while the cutting
tool moves in a linear motion across the end surface, removing
material to create the desired flatness and finish.
o Multiple Passes: Depending on the depth of cut and required
finish, multiple passes may be needed.
3. Types of Facing:
o External Facing: Performed on the outer diameter of a cylindrical
part.
o Internal Facing: Involves facing the inside diameter of a hole or
bore.
o End Facing: Specifically targets the ends of the workpiece to
achieve flatness.
4. Cutting Tools:
o Single-Point Cutting Tool: The most common tool used for facing
operations, which removes material efficiently.
o Insert Tools: In some cases, insertable tooling may be employed
for specific applications.
5. Considerations:
o Feed Rate: Selecting an appropriate feed rate is essential for
achieving a good surface finish while avoiding tool wear.
o Cutting Speed: The speed at which the workpiece rotates is crucial
for efficient material removal and quality of the finished surface.
o Depth of Cut: Should be adjusted according to the material and the
desired outcome; larger depths may require more passes.

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Drilling
Drilling on a lathe is a machining operation that involves creating holes in a
workpiece. While lathes are primarily used for turning operations, they can also
be utilized for drilling, especially when the workpiece is mounted securely in
the lathe’s chuck. This method can be particularly useful for producing holes
that need to be accurately positioned on cylindrical parts.

1. Objectives of Drilling
o Creating Holes: The primary purpose is to produce holes of various
diameters and depths in a workpiece.
o Achieving Precision: Lathe drilling allows for high accuracy and
alignment, especially for holes that need to be concentric with the
workpiece.
o Versatility: It enables the creation of different hole shapes, such as
blind holes or through-holes.

2. Process Overview
o Setup: The workpiece is securely mounted in the lathe’s chuck. It
should be aligned to ensure that the centre of the hole will be
accurately positioned.
o Tool Selection: A drill bit is chosen based on the desired hole size and
type. Standard twist drill bits are commonly used for this operation.

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 o Tool Positioning: The drill bit is positioned vertically above the
workpiece. The lathe’s tailstock, which can be moved along the bed, is
often used to hold the drill bit and provide the necessary feed.
o Drilling Action: The lathe is powered on, rotating the workpiece
while the drill bit is fed into the material. The operator adjusts the feed
rate to control how quickly the drill penetrates the workpiece.
o Depth Control: The depth of the hole can be controlled by monitoring
the feed of the drill bit, and depth stops may be used to ensure
consistent hole depths.

3. Types of Drilling Operations

o Through-Hole Drilling: Creates a hole that passes completely
through the workpiece.
o Blind Hole Drilling: Produces a hole that does not go all the way
through, typically requiring precise depth control.
o Counterboring and Reaming: Additional operations that can follow
drilling to achieve specific hole diameters or finishes.

4. Considerations for Effective Drilling

o Cutting Speed: Selecting the appropriate rotational speed for the
workpiece and drill bit material is crucial for effective cutting and tool
life.
o Feed Rate: The rate at which the drill bit is fed into the workpiece
should be adjusted based on the material being drilled and the size of
the drill bit.
o Lubrication and Cooling: Using cutting fluid can help manage heat
and improve the surface finish of the hole.

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Turning
Turning is a fundamental machining process primarily used on lathes to produce
cylindrical parts. This operation involves removing material from the outer
diameter of a workpiece as it rotates, creating various shapes and dimensions
based on the desired specifications.

1. Objectives of Turning
o Shape Creation: The primary goal is to transform a raw workpiece
into a finished cylindrical shape.
o Dimensional Accuracy: Turning achieves precise measurements and
tolerances, essential for fitting components in assemblies.
o Surface Finish: The operation can improve the surface finish of the
part, making it suitable for functional and aesthetic requirements.

2. Process Overview
o Setup: The workpiece is securely mounted in the lathe’s chuck or
between centres, ensuring stability during rotation. Proper alignment is
crucial for achieving accuracy.
o Tool Selection: A cutting tool, usually a single-point tool, is selected
based on the material and desired finish. Tool materials may include high-
speed steel (HSS), carbide, or ceramic.
o Tool Positioning: The cutting tool is positioned parallel to the axis of the
workpiece. Adjustments are made to set the cutting depth and angle.

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o Cutting Action: The lathe is powered on, causing the workpiece to
rotate. The cutting tool is then fed into the material, removing material as
it moves along the length of the workpiece. This can be done in various
ways:
o Straight Turning: Produces a uniform diameter along the length of the
workpiece.
o Taper Turning: Gradually reduces the diameter along the length,
creating a conical shape.
o Contouring: Involves more complex shapes by varying the tool path.
o Multiple Passes: Depending on the desired dimensions and surface finish,
multiple passes may be required, with adjustments made to the depth of
cut and feed rate.
3. Types of Turning Operations
o External Turning: The most common form, focusing on the outer
surface of the workpiece.
o Internal Turning: Involves creating internal features such as bores
or cavities.
o Facing: Produces a flat surface on the end of the workpiece.
o Grooving and Parting: Used to create grooves or to cut off parts
from a larger workpiece.

4. Considerations for Effective Turning

o Cutting Speed: The rotational speed of the workpiece must be
appropriately set according to the material and tool specifications to
optimize cutting efficiency and tool life.
o Feed Rate: The rate at which the tool is fed into the workpiece
affects the surface finish and cutting efficiency. This must be balanced
to prevent excessive wear.
o Depth of Cut: Should be chosen based on the material and tool
capability, as deeper cuts may require more power and can increase
tool wear.
o Tool Wear and Maintenance: Regular monitoring of tool conditions
is essential to maintain performance and ensure quality. Worn tools
should be replaced or sharpened.

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 COST COMPUTATION

60mm: 32mm Mild Steel Round Bar

To estimate the price for a 30mm diameter, 40mm long product made
using a 60mm long rod with a market price of ₹60 per kg and by assuming
a linear scaling factor, we can multiply the price per kilogram for the
32mm diameter mild steel round bar by a factor of approximately 1.6,
Which Yields to around 100 Rupees.

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 DIMENSIONAL INSPECTION

Outer Diameter (measured using Vernier Calliper)

Difference
Required Obtained
(mm)
(mm) (mm)

30 29.94 0.06

Inner Diameter (measured using Vernier Calliper)

Difference
Required Obtained
(mm)
(mm) (mm)

20 19.5 0.5

Height (measured using Height Guage)

Difference
Required Obtained
(mm)
(mm) (mm)

40 40.66 0.66

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 GEOMETRIC INSPECTION

Roundness Error
Sl No Dial Reading Roundness Error
1 0diu = 0mm
2 +10diu = 0.01mm
3 -10diu = -0.01mm
3.5mm
4 +18diu = 0.018mm
5 +20diu = 0.02mm
6 -15diu = -0.015mm

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 Conclusion

The study of piston pins has underscored their vital role in the functionality and
efficiency of internal combustion engines. Serving as a critical connection
between the piston and the connecting rod, piston pins are essential for
transferring forces during operation.
Through detailed exploration, we established the importance of precise
dimensions and material specifications to ensure durability and performance
under extreme conditions. Our investigation into manufacturing processes
highlighted the necessity of advanced machining techniques to achieve the
required tolerances and surface finishes.
Moreover, the analysis of cost implications demonstrated that while high-quality
materials and processes may increase initial expenses, they ultimately lead to
enhanced reliability and reduced maintenance costs over time.
Overall, the insights gained from this project emphasize that careful engineering
and rigorous quality control in the production of piston pins are fundamental for
optimizing engine performance. Continued advancements in material
technology and manufacturing techniques hold promise for further
improvements in this critical component of automotive engineering.

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