The document discusses manufacturing processes in the automotive industry. It describes how key engine components like pistons and crankshafts are made from materials like cast iron through forging and pressing thousands of tons of pressure. It also explains how chassis and body parts like doors are manufactured from aluminum and other lightweight metals through processes like sheet metal forming, deep drawing, and pinch rolling. The document concludes by mentioning how shock absorbers are produced through processes like tube rolling and impact extrusion to control vibrations in vehicles.

2.  The Automotive industry is one of the largest industries in
the World
 Trends compete every year for the most powerful, economic
, beautiful in the market
 And what define the winner is the manufacturing process
behind the spinning wheels
24 December 2013

3. Manufacturing of Car parts
Engine
pistons
crankshaft
Connection
rod
Body
chassis
doors
suspension
system
Rims
Shock
Absorber

4.  An engine is a related group of parts assembled in a specific
order , it’s designed to convert thermal energy given off by
burning the fuel into a useful form.
 We will just discuss
Some of it’s components
and how it’s manufactured

5.  A solid disk or cylinder that fits inside a hollow cylinder, and
moves under pressure
 It’s made from cast iron or aluminum
alloy
 It’s should be wear resistance and can
take very heavy impact loading

6.  The piston begins as a, solid aluminum rod
 Then after it’s been cut as slug and preheated the slug is
placed into the punch.
 The press applies 2,000 tons of pressure onto the slug,
forging it into the basic shape of a piston.

7.  It’s main duty Is to convert the angular motion of the
connection rod to a rotary motion to the transmit the
mechanical motion.
 It’s made from carbon steel alloy and the carbon percentage
vary on the application of the crank shaft in different engines

8.  Then it’s heat treatment due to residual stresses gained from
forging so we make annealing process to increase ductility
and reduce residual stresses

9.  It’s a rod that connects from it’s upper pin the piston and
from it’s down pins the crank shaft
 It’s convert the Reciprocating motion of the piston to an
angular motion to the crank shaft
 It’s made from aluminum alloy now days to withstand the
high repeated stress (high endurance limit).

10.  First we use forging (on different steps ) to increase the
mechanical properties of the rod and it’s resistance to
impacts .
 Then use blanking to cut the material which are not needed
(scrap)

11.  Now let’s try to see how Sheet Metal Forming
Convert

12.  It consist from frame and chassis which it’s main function to
support the construction on the vehicle and give safety to it’s
equipments and passengers

13.  Now days it’s design from weaker and lighter
material
 Aluminum , Magnesium WHY!!!!!!!

14.  Automotive chassis or automobile chassis helps keep an
automobile rigid, stiff and unbending. Auto chassis ensures
low levels of noise and vibrations

15.  It used to be steel, but corrosion attacked unless a good
coating is added , then aluminum is used adding to its alloys
zinc and magnesium to increase hardness and toughness,
then titanium is added to alloys, and sometimes fiberglass
and carbon fibers is used

16.  Using pinch rolling (form rolling) processes to produce the
chassis metal pars.

18.  It's made of sheets of carbon steel.
 Then the machine divide the big coil into small plates

19.  Using deep drawing processes we produce the outer door
panel

20. • At the next step we assemble the door frame with the inner
door panel.
• Then assemble the outer door panel with the inner door panel
by pressing them.

21. we need a way or a system that can dumb vibrations
and stress to it’s minimum limits as possible to
ensure the comfort of the passengers and safety of
the vehicle
24 December 2013 Group 6

22.  A shock absorber is basically an oil pump placed between the
frame of the car and the wheels.The upper mount of the
shock connects to the frame (i.e., the sprung weight), while
the lower mount connects to the axle,
24 December 2013 Group 6

23. • At the next step we use the tube rolling processes to produce
the cylindrical shape of the tube.
• Then using a huge welding wheel we close the tube
24 December 2013 Group 6

24. • Using impact extrusion we compress the end of the tube in
order to make the tube hold more oil.
• Then we assemble the valve with the cylinder.
24 December 2013 Group 6

25.  The rim is the "outer edge of a wheel, holding the tire". It
makes up the outer circular design of the wheel on which the
inside edge of the tire is mounted on vehicles such
as automobiles.

26.  Hot Forging -Takes a billet and creates metal
lines through volume distribution with a hot
press

27.  The Metal FormingTechnology (Sheet , Bulk)
is one of the core manufacturing technology
that have big impact on the automotive
industry and all automobile manufactures
every year try to come up with the best
forming method to improve their design
 Questions ………………………. ?

29. Mohamed
Mostafa
Ahmed
Mohamed
Ibrahim
Ahmed
Mahmoud
Khairy Abd-
Elsalam
Eman Abd-
Elfatah
Ahmed
Takla Nabil
Sawires
Beshoy
Raafat Naaem
Toka
Mohamed El-
Sayed
Khulod
Abdullah
Saleh
Mohamed
Samir
Mohamed
Emad El-din
Abd el hafeiz
Team Members

30. Thank you for your time