Engine Strip & Build Assignment Due 4:00pm Mon 27th April 2015 Wharf building stores.
Submission is to be a Word processed technical report (maximum 10 sides A4) submitted with a uclan assignment submission form.
This assignment will primarily relate to identifying a range of common manufacturing process and techniques used for the manufacture of a range of parts in an engine.
On successful completion of this module a student will be able to:
1. Demonstrate an understanding and appreciate commonly used manufacturing processes and techniques
2. Demonstrate an acquisition of basic hands-on workshop skills.
4. Demonstrate the study technique of research through reading and assimilation of information.
5. Practice and show report writing skills.
Part 1 Engine strip, inspection, measurement and re-build of a functioning Honda GX160 Engine. Follow the instructions for:
• Part 1 (A) Engine Practical Workshop 1 Engine Disassembly
• Part 1 (B) Engine Practical Workshop 2 Measure, Re-assembly and Running
Once the cylinder head has been removed you are to take measurements to determine the compression ration of the engine. Describe the process undertaken for disassembly, assembly and measurement. Include the results for calculating compression ratio in your report.
Part 2 Detailed component investigation – you will inspect of a range of manufactured parts from a Ford 1600 engine to establish commonly used manufacturing processes and techniques.
• Part 2 (A) Carry out a detailed component investigation of the four parts given
• Part 2 (B) Complete the table for the General Identification of a range of manufacturing processes and techniques.
This assignment contributes 20% to the total for this module.
Part 2 (A) – Detailed Component Investigation
You will be given FOUR of the parts below to carry out a detailed investigation.
For each of the four parts you are to:
• Investigate and identify the material from which the part is manufactured stating why the material is a suitable choice for this component.
• Identify any manufacturing process and techniques used in the manufacture of the component, justify your reasoning.
• Describe in detail how the part may have been held or secured during manufacturing taking into consideration, where applicable, mass manufacturing.
• Describe any alternative manufacturing process that could have been used
• Comment on any specific tooling or machine requirements needed to manufacture the part
Part 1 – ALTERNATOR BRACKET
Part 2 – CAMSHAFT END BRACKET
Part 3 – CAMSHAFT
Part 4 – CONNECTING ROD
Part 5 – CRANKSHAFT
Part 6 – EXHAUST MANIFOLD
Part 7 – FUEL INJECTOR RAIL
Part 8 – MAIN BEARING SUPPORT
Part 9 – PISTON
Part 10 – SUMP COVER PLATE
Part 11 – SUMP
Flywheel Crankshaft Camshaft Exhaust manifold Piston Cylinder block Cylinder head
Turning
Grinding
Drilling
Spot facing
Tapping
Reaming
Vertical boring
Honing
Milling
Heat treatment
Die casting
Sand casting
Forging
Part 2 General Identification
There are a vast range of manufacturing processes available to manufacture components, many of which are used in the manufacture of an engine. The most appropriate method needs to be selected to ensure the part meets the necessary accuracy and tolerances while keeping the overall component cost into account. The quantity of parts to be manufactured also needs to be considered and may influence the method chosen. Identify which of the processes have been used to manufacture the parts listed below, tick to indicate.
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