Manufacturing of Valves

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Valve Material Store

The inlet and outlet valves are bascially made of two steels namely, i) Austenite ii) Martensite material is chosen depending on the customer requirements.

The

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Pre Machining processes

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Frictional welding
This

is a special process, done when two parts is to be combined during manufacture. are two types in frictional welding namely 1. Head to pin 2. Pin to pin

There

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Frictional welding
In

pin to pin process a martensite bar is welded by means of frictional heat to a austentie bar. head to pin process, head and stem of the valve are made seperately and attached together

In

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Frictional welding
Principle:

This principle is that when a rotating bar comes in contact with a stationary bar friction occurs and heat produced due to friction melts and rejoins the metals.

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Frictional welding
First

austenite bar is held in a collet and placed in a spindle. Then along its horizontal axis, the martensitic bar is held along a v block. The spindle starts rotating as the machine is turned on and the v block capable of moving along a horizontal axis is moved and made to come in contact with the rotating bar thus producing friction in it. Due to the heat of friction the the ,martensitic metal melts and gets welded with the other bar, forming a bulged portion 5/21/12 in the region welded.

Frictional welding
S.No Friction weld parameters 1. Temperature 2. 3. 4.

Depends on the materials welded Spindle rotation Speed 1050 rpm Upset force Frictional force 1.1kg/cm^2 0.41 kg/cm^2

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Frictional welding
The

parameters which has to be checked after friction welding are i) Strength of the welded region(weld) ii) Overall length of the bar

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Deflash
This

operation is done to remove the buldge portion after frictional welding. using turning operation it is removed.

It

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10

Deflash
Here

the welded bar is kept in a collet whiich is placed in a spindle. A cutting tool placed in a tool post is moved horizontally over the rotating bar and the buldge portion is removed.

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11

Upsetting
This

process is used to form a bulb portion, which then converted to head portion by forging.

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12

Upsetting
The

setup consists of two anvils.The upper one is fixed while the lower one is capable of moving in a vertical axis. To the fixed anvil current is being continously passed. Now when the lower anvil holding the bar is raised up and brought in contact with the upper one, due to high current the metal get hot and expands.At the same time due to upset pressure the bulb shape is formed. And when the anvil is brought back down at specific time due to return pressure the bulb 5/21/12 is completed.

13

Upsetting
The

parameters to be checked while the process are i) anvil gap : 2-5mm bar dia ii) Upset Pressure iii) Return pressure iv) Electric current Parameters ii,iii,iv depends upon customer requirements

There

are two types of anvils used in this process, namely, special and regular 5/21/12

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Upsetting
The

parameters needed to checked after upsetting are

S.No Parameter 1 Inspection

Cracks in bulb Visual inspection

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Forging
Principle:

Forging is a bulk deformation process which works in the principle that when requisite force is applied to manipulate the metal in such a way that the required final shape is obtained.

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Forging
This

process is basically done to get the head of the valve. Generally for forging operation carbide die is used.

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Forging
In

this operation, the hot upsetted bar is placed in the bottom die vertically with the bulb facing upward. By air pressure operation the upper die is made to strike the bulb, thus forming the head shape.

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Forging
The

following parameter should be checked during the process

S.No Parameter 1 2 Stop pieces Limit value

Various length required Guiding die bush +.1-.13mm higher than bar dia

Stop

pieces are used to increase the length required for increasing the height.
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Forging
The

following parameters should be checked after the forging process

S.No Parameter 1. 2. Overall length Stem runout Verification method Length measuring gauge

Usually

in forging operations steel die is used as it can be used to make 500 jobs.

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t Treatment
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21

Heat Treatment
Generally

for pure Martensitic valves Hardening and Tempering is done. For bimetallic valves solutionising and ageing is done. The reason is since Austentite is the hardest among the steels it is remains at same hardness level irrespective of any conditions.So solutionizing is done so that the hardness of martensitic material rises to a high grade and gets maintained at the hardness of austenite.
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Hardening
Principle:Continous

expose to high temperature for a short duration(1 hour) and sudden quenching in oil/water/air expands the material and increases the hardness of the bar. process is done for martensitic materials to improve the hardness and strength of the material.

This

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Hardening
The

following parameters are followed during hardening process depending on the material

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Hardening
Material Hardened Temperatu Soaking time Hardness re (min) (degrees) Valve Stem

EN 18D EN24 EN52/X45 CrSi 93 SUH3

45 45 48 46

830-860 10-20 830-860 10-20 1000-102010-20 1000-102010-20 900-930 830-860 10-20 10-20

60 60 60 60 60 5/21/12 60

SUH11 48 SAE4110/ 45

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Hardening
In

this process the valve is kept inside a chamber maintained at a temperature mentioned for the material of the valve. The valve is exposed to this temperature for about 1 hour so that the material expands and its hardness increases. After the specific time the valve is oil quenched to cool it.

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Hardening
Generally

a bauxite furnace is used for cooling in which hot oil is placed with separate tubes for air and water. After the process the material is checked for its hardness using a hardness tester.

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Tempering
This

process is done for to produce high quality hardened valves and also to reduce the brittleness of the valves to a certain extent.

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Tempering
this process the valves are placed inside a container where they are exposed to a much lower temperature compared to hardening(600-700deg.) for a quite long time(3 hours). The difference between hardening and tempering is in hardening it is exposed to high temperature for short time duration but in temperature it is exposed to low temperature for long time duration.
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In

Tempering
After

it has been removed from the furnace it is cooled by means of air for some 10minutes time. this process the hardness is again tested by means of hardness tester.

After

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Short Blasting
This

process is used for removal of scales present over the valves. By continous contact of the valves over sand removes the scales over the valves.

Principle:

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Short Blasting
Here

first the valves are loaded on the short blast furnace. Then the doors of the furnace is closed and locked. Now the elevator motor is switched on first followed by the impeller motor. Now the impeller rotates and the continous riddling of the valves over the sand occurs. Now after the specific time, when the impeller stops(after switching off),the valves are unloaded.
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Short Blasting
Short

blasting is generally done for 10- 15 minutes time. Few parameters to be checked after short blasting are
S.No Parameter 1 2 Inspection

Cosmetic finish Visual on radius/Dish Embossed letters Visual

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Short Blasting
The

places of occurance of failure are

Rectification Quantity per lot can be reduced or more time for short blasting can be carried on.

S.No Failure 1 Black spots on radius

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Straightening
This

process is primarily used to straighten the stem axis wrt to the axis of the head.

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Straightening
The

parameters to be checked during process are

S.No Parameter 1. 2. 3. Specification

Roller pressure20-30 kg/cm^2 Straightening 1-1.5 sec time Angle Roller F49595 F40745 45 deg angle roller F39599 to be used 5/21/12

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Straightening
The

valve is first placed in the machine. When the machine is switched on the and the cycle is begun, the valve is acted by 7 rollers,2 * 2 on its either sides and 2 on its to surface and an angle roller. These rollers straighten the stem axis. The pressure of the top roller is about 30 kg/cm^2 and the return pressure is about 15 kg/cm^2

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Straightening
After

the straightening process the straightness of the stem,profile radius and head thickness are checked.

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Special Processes
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Special process
All

the special processes mentioned below are done only when the customer specifies them.

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Turn Head Diameter Recess

Here

a recess is formed in the valve seat of head region for coating stellite in the region in this process the head diameter is also reduced according to the required value. principle of this operation is nothing but turning.

Also

The

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Turn Head Diameter Recess

In

this process the valve stem in placed inside a collet and then into a spindle capable of roation.Now the machine is switched on and the spindle rotates The head region is now influenced by two cutting tools individually. First the diameter of head is reduced to required limit by the first cutter then the recess is formed in the seat region by the second cutter. In both the cases turning operation is carried out. 5/21/12 Coolent is used to removed the heat

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Turn Head Diameter Recess

The

following parameters should be checked during the process

S.N Parameter o 1. Feed SPM Specification Manual THD Recess 2. Coolant Soluble cutting 1.0/1.2 oil and water in mm/s ratio 1:40 . 5/21/12

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Turn Head Diameter Recess

The

parameters to be checked after the process are

S.No Parameter 1. 2. 3. Head Diameter Head runout Recess profile Verification Snap gauge Fixture FX-1 with .01 dial Profile Projector

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Turn Head Diameter Recess

The

possibilities of failure in this process is chittering which can be removed by using a wire cut tool.

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Seat Hardening
In

this process the seat is hardened by deposition of stellite in the recess formed in the seat portion by TIG welding. basic method for this deposition process is TIG welding process. is deposition on the seat to harden it so that it may not wear out during working.

The

Stellite

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Seat Hardening
In

this process the job is loaded in the base plate and cycle is switched on. Now the base plate rotates and electrode to which current is flowing and which is jus above the seat recess gets heated and melts over the recess due to which stellite gets coated over the recess. The shielding gas protects the weld pool,electrode from oxidation. Flux gets settled down over the weld as slag. In this process a grade 6 electrode is used.
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Seat Hardening
The

parameters to be checked while welding

Small valves Weld current(A) 90-120 Upslope time(s) 1-4 Downslope time(A) Job Rotation 1-4 Big Valves 140-150 1-4 1-4

are
S.No Parameter 1. 2. 3. 4.

Machine Machine specific specific

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Seat Hardening
The

parameters to be checked after welding

Verification equipment Profile projector Die penetrant test Visual

are
S.No Parameter 1. 2. 3. Deposit form and filling up Bonding Porosity, Blow holes

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Seat Hardening
The

various failure possibilities in this process are

S.No Parameter 1. Inclustion Rectification Set the req. current Check quality of rod Regrind electrode and reset it. Change base 5/21/12

2.

Valve melting

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Coining
This

process is used for pressing the welded portion with the seat. basic principle is the heating and forging.

The

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Coining
In

this process the welded area is heated by means of oxyacetylene flame.Also when any print is to made on the bottom of head then that region is also heated. Then in red hot condition the valve is placed with its heads flat portion facing the top die and its seat resting on the bottom die. The top die has the imprint to be printed over the flat end of head. When the top die strikes the flat face of head the imprint falls over the valve and at the same time the weld flattens over the along 5/21/12 with the seat.

52

Coining
The

process parameters to be taken care during the process are

S.No Parameter 1. 2. 3. Oxy pressure Acetylene pressure Coining temp Specification 2-4 kg/cm^2 .5 kg/cm^2 950-1000 deg

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Coining
Parameters

to be checked after process are

Verification

S.No Parameter 1. 2 3. 4. 5.

Overall length Fixture FX-6 with length bar Head thickness Profile projector Radius profile with oil drawings Material on seat Head diameter Micrometer with Ray tech gun . 5/21/12

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Coining
Places

where failure can occur are

Solution Check Valve heat temperature and check blow setting Check stopper setting Check die bush bore
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S.No Parameter 1. Filling up rear deposit junction bed Stem runout

2.

Wet End
This

operation is done in the tappet end of the valve to reduce the length of the valve. basic principle is grinding operation.

The

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Wet End
In

this process the valve is kept over the Vblock and the machine is started. Now the Tappet end of valve is faced over the rotating grinding wheel thus resulting in reduction in length. Th contact time is .5 sec to 1 sec. This process is done before and after cavity drilling and tipping process respectively.

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Wet End
The

process parameters to be noted during the process are

S.No Parameter 1. 2. 3. 4 Depth of cut Feed Pneumatic pressure Specification 1-2 mm 7-10mm/s 4-5 kg/cm^2

Grinding wheel speed 16001800rpm

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Wet End
The

parameters to be checked for failure after the process are

S.No Parameter 1. Overall Length Verification Remedy

2.

Fixture FX-6 Check with .01 mm face gauge stopper button and grinding wheel bearing Tappet end Fixture FX-4 V-Block 5/21/12

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Form Cavity
This

process is used to form a cavity in the tappet end of the valve for filling stellite during tipping. process is nothing but drilling where a cavity is drilled over the tappets flat end.

This

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Form Cavity
The

valve is held in the collet and placed in the machine with the tappet end facing the cutter. Now the machine is switched on and the rotating driller is moved a horizontal axis and drills a cavity on the tappet end. Hydraulic force is used to move the drill.

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Form Cavity
The

parameters to be checked during the process are

S.No Parameter Specification

1.

2.

Austenite 21Drill speed 4N,SUH38 750-850rpm Martensite SUH3,SUH1 1, SNB16 Air pressure 5-6 kg/cm^2 5/21/12

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Form Cavity
Parameters

to be checked for failure after the operation are

S.No Parameter 1. Cavity Depth Verificatio n FX-6 fixture with .01 dial Profile projector Visual Remedy Check depth setting Rework bad valves Check drill 5/21/12 bit for

2.

Cavity form

3.

Cavity finish

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Tipping
This

operation is nothing but depositing stellite in the cavity drilled in the tappet end to increase the hardness of the tappet end so that it maynot wear when the rocker arm strikes it during the operation. operation takes place by the welding principle.

This

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Tipping
In

this process a grade 1 stellite electrode is melted using an oxyacetylene flame over the cavity drilled portion in the tappet end. fills the cavity thus hardening the tappet end. during welding is around 3500 deg at the electrode.

Stellite

Temperature

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Tipping
Parameters

to be checked during the process

Specification

is
S.No Parameter 1. 2. 3. 4. 5

Oxygen Pressure 2-5Ksc Acetylene .5-.7 Ksc Pressure Flame Type X-3x/ x-4x Height of deposit1- 1.5 mm Deposit of material Stellite grade I
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Tipping
Parameters

to be checked after process are

Verification Height gauge X-ray testing

S.No Parameter 1. 2. Height of Deposit

Possibilities

of failure are Porosity/density

S.No Parameter 1.

Remedy

Valve melting Check for flame setting Reduce wall thickness due to 5/21/12

67

Machining Processes
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Rough Centreless Grinding

This

process is done to reduce the stem diameter.Amount of diameter reduced can be upto 300microns in this process. operation taking place is centreless grinding.

This

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Rough Centreless Grinding

In

this process the stem region of the valve is subjected between two rollers namely the grinding wheel and control wheel. The distance between the two wheels must be equal to the diameter of stem after grinding. Due to the action of the two rollers and the blade over the stem the diameter of the stem reduces to the required value set.

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Rough Centreless Grinding

The

parameters to be checked before grinding operations are

S.No Parameter Specification

1. Coolant Biocool 2. Hydraulic pressure 20bar Hydraulic pressure must be maintainted

properly else if pressure is *high it leads to oil leakage *low it leads to bed movement
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Rough Centreless Grinding

The

parameters to be checked after grinding

Verification Fx11 fixture with .01 dial

are
S.No Parameter 1. 2 Stem Diameter Stem runout

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Head Turn Diameter/Finish Face

This

process is used for facing the flat face of head ,resulting in reduction in head thickness, and the chamfering the head face. operation uses the principle of facing and chamfering in a CNC.

This

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Head Turn Diameter/Finish Face

The

Valve is inserted in the collet and held in a chuck. Now a the inserts are placed in a tool post capable of moving in both the axis. When the machine is switched on the first insert reduces the thickness by facing operation and the second cutter chamfers the head region by chamfering operation.

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Head Turn Diameter/Finish Face

Parameters

to be checked before the process

Specification

are
S.No Parameter 1.

Collet clamping 30pressure 33kg/cm^2 Collet clamping pressure- hydraulic pressure 2. Air Pressure 5-6kg/cm^2 GrippingCoolant of all other arms-Air pressure 3. Cooledge

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Head Turn Diameter/Finish Face

Parameters

to be checked after the process

Verification

are
S.No Parameter 1. 2. 3. Head diameter

4.

Go and No Go Gauge Head dia runout FX1 with .01mm dial gauge Head thickness Pot Gauge FX7 fixture with .01 dail Chatter marks in Visual 5/21/12

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Profile Turning(ACE Cube CNC)

This

operation is done in the profile of valve to give clearance in seat and stem neck so that the valve fits properly in the engine cylinder. turning operation in done with the CNC over the stem neck and profile.

Here

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Profile Turning(ACE Cube CNC)

In

this process when the machine is switched on the with the valve in the collet the triangular insert carries over turning operation from the stem neck till over the profile. Finue oil is used as coolant in this process.. Ace cube CNC consists of a tool post which can carry upto 8 inserts.

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Profile Turning(ACE Cube CNC)

The

parameters to be checked after the process are

S.No Parameter 1. 2. 3. Verification

4.

Radius profile Profile projector Seat runout Head Pot gauge fixture Thickness FX7 with .01 mm dial Undercut Snap gauge diameter
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Profile Turning(ACE Cube CNC)

The

various failure possibilities are

Remedy Change insert Check collet runout

S.No Parameter 1. Head Dia variation 2. 3. Head dia runout Seat runout

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Turn reduced stem,groove and end facing

In

this process overall length of tappet end is reduced,tappet end is chamfered,and groove is formed. principle behind these are turning and chamfering with the respective inserts in the CNC machine.

The

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81

Turn reduced stem,groove and end facing

First

the valve is held in collet and it is placed in the spindle.When the machine is switched on the spindle starts rotating and in the tappet end a 45 deg insert reduces precisely and produces chamfer by chamfering operation. Then using a triangular insert specified length of the tappet end is turned to form small threads of less thickness and dia. Then at the specified space in the tappet region the groove is formed using a groove insert. 5/21/12 The groove is used for holding the valve in

82

Turn reduced stem,groove and end facing

The

parameters to be checked while the process are

Tip indexing Freq.

S. Material System Collet Pneumat Dwell Spindl N Pressur Clampin ic Time e rpm o e g Pressure Pressur e 1 X45 CRS193 25-30 15-20 3-5 .1-.5 2400 kg/cm^Kg/cm^ kg/cm^2 Sec Const 2 X45 2 CRS193 2

1200

1600
83

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Turn reduced stem,groove and end facing

Parameters

to be verified after the process

Verification Fixture F6 with . 01mm dial Profile projector

are
S.No Parameter 1 2. 3 4 5 Overall length

Tappet end radius/camfer Groove Shape gauge diameter Groove runout Fixture FX1 with . 01mm dial gauge 5/21/12 Groove finish Visual

84

Tappet end grinding

This

operation is done to finish the flat surface of the tappet end. process is similar to wet end grinding expect to that this process is done in CNC automatically.

This

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Tappet end grinding

In

this operation the valve is placed in a Vgroove and its tappet end is faced against the rotating wheel. The operation time is less than a second. Only when this operation is done, the heat is uniformly conducted throughout the tappet in induction harden end operation else it will lead to irregularities. Tappet end runout is be checked after the process using a pot gauge.
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Induction Harden End

This

process is done to harden the tappet end of the valve so that it doesnt wear out during the operation. principle behind the process is heat is produced by passing electric current through a coil and when the tappet end is exposed to the space between the coil it gets heated and gets hardened.

The

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Induction Harden End

In

this process the Tappet end of the valve is attached to a collet which is attached to a spindle driven by a motor and which can move in a horizontal axis. The tappet end is suspended between a copper coil through which electric current is passed. When the machine is switched on the spindle rotates and electric current is passed through the coil.Due to the process of induction heat is generated in the coil and the tappet end thus hardening the tappet 5/21/12 end.

88

Induction Harden End

The

following process should be checked during the process

S.No Parameter 1 2 Motor Speed Cooling oil Specification 60 rpm const Meta quench 39 or equal

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89

Induction Harden End

The

following parameters to be checked after the process

S.No Parameter 1 2 Verification

Hardness on tappet Rockwell end hardness tester Barrel length V block with micrometer attachment Depth of hardness By acid etching
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Induction Harden End

The

possibility of failure is
Remedy

S.No Parameter 1

Variation of hardness Check input and depth voltage variation Also Check tappet end and coil distance and air gap.
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Induction harden seat

This

process is used to harden the seat so that it doesnt wear out when it operates during engine operation. principle of this process is similar to that of the induction harden end.

The

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Induction harden seat

In

this process the Tappet end of the valve is attached to a collet,vertically, which is attached to a spindle driven by a motor and which can move in a vertical axis. The tappet end is suspended between a copper coil through which electric current is passed. When the machine is switched on the spindle rotates and electric current is passed through the coil.Due to the process of induction heat is generated in the coil and the tappet end thus hardening the tappet 5/21/12 end.

93

Induction harden seat

The

following process should be checked during the process

S.No Parameter 1 2 Motor Speed Cooling oil Specification 60 rpm const Meta quench 39 or equal

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94

Induction harden seat

The

following parameters to be checked after the process

S.N Parameter Verification o 1 Hardness on seat Rockwell hardness tester 2 Hardness survey Micro hardness tester 3 Hardness depth By acid etching

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Induction harden seat

The

failure possibilities during the process

Remedy

are
S.No Parameter 1

Variation of hardness Check input and depth voltage variation Also Check tappet end and coil distance and air gap.
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Centreless grinding I
This

operation is done for reduction in stem diameter. limit is around 100 microns

Removal Rough

grinding operation and CF I cannot be done as a single operation because it leads to runouts and overheating.

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Centreless grinding I
The

following parameters should be checked during the process

S.No Parameter 1 2 3 4 Specification

Max material .1 to .25 mm removal Grinding wheel 1400 rpm speed Control wheel 380 rpm speed Control wheel head .5 1 deg
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Centreless grinding I
In

this process the stem region of the valve is subjected between two rollers namely the grinding wheel and control wheel. The distance between the two wheels must be equal to the diameter of stem after grinding. Due to the action of the two rollers and the blade over the stem the diameter of the stem reduces to the required value set.

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Centreless grinding I for seat

The

parameters to be checked after the process are

S.No Parameter 1 2 3 4 Verification

Stem Diameter Fixture FX! With . 001/.002 dail Stem runout Fixtture FX5 with . 001/.002mm dial Blending radius Profile projector Parallel grindingLength gauge length 5/21/12

100

Centreless grinding I for seat

Chances

of failure in the process are

Remedy Check setting of blade length Control wheel speed.

S.No Parameter 1 Stem runout exceeding upper tolerance limit Chatter mark on stem

2.

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Nitriding and Vibropolishing

The

objective of nitriding of this process to to improve wear,friction,fatigue and corrosive properties and to improve the valve appearance. polishing is done for smooth surface finish of valves after nitriding and also for removal of salts.

Vibro

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Nitriding
The

valves are arranged in the jig plate and loaded in the degreasing tank using hoist. After decreasing the valves are rinsed in water and transferred to the preheating furnace using hoist and is preheated. Within two minutes after preheating it is then transferred to the nitriding bath after which it is quenched in oxidising bath. It is then removed and allowed to cool for 2 minutes and quenched in water to clean them.
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Vibro polishing
In

this process the nitrided valves are placed over a large container containing abrasives and capable of vibrating.When the machine is switched on the container vibrates to and fro and constant collision of valves with the abrasives causes the polishing effect in the valves. The process is done for almost half an hour. After vibro polishing,it is dipped in sodium nitrite solution and followed by rust preventive oil.
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Grind Seat
This

process is used for grinding the valve seat so that it may easily sit in the cylinder without wear. operation done is grinding.

The

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105

Grind Seat
In

this process the valve from chute moves to the grinder when it is acted by a grinding wheel and a cutter which removes 5 micron dia in the valve seat making it comfortable to sit during operation in the engine cylinder.

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106

Grind Seat
The

parameters to be checked after the operation are

S.No Parameter 1 2 3 Seat angle Seat height Seat runout Verification Profile projector Pot gauge Fixture FX3 with 0.001mm gauge Surface finish tester 5/21/12 Pot gauge FX9

4 5

Seat finish Datum to end

107

Grind Seat
The

possibilites of failure are

Remedy Check collet runout and wear Check overall length variation Check belt tightening bolts are fully tight.
5/21/12

S.No Parameter 1 Seat runout

Seat height

Seat angle variation

108

Finish Centreless Grinding

This

process is done to finish the stem surface removing jus upto 20 microns. here centreless grinding operation is carried over.

Even

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109

Finish Centreless Grinding

The

remaining all parameters are same as that of CF1 expect to that of here in this process material is removed for smooth finish.

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110

Nitriding
After

finish centreless grinding is done nitriding process is done again for smoothness and valve appearance.

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Final Inspection
Here

every aspect of the gauge is inspected and verified whether they are within tolerance range. Only when they are in tolerance limits they are selected else they are reworked.

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Thank you
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