Raw material is classified based on its chemical composition and stored in individual bins, raw material is transferred from the bins to the furnace Manually. Induction furnaces are used to melt the metal, once the required temperature is obtained a chill sample is prepared and the chemical analysis is checked on a spectrometer.
Raw Material
Melting
Melting is one of the beginning prominent processes of the casting. Due care is taken while melting like charge preparation as per customers material specification requirements. The first step in the process is to collect and sort the cast iron scrap, Pig Iron and other materials and alloys that will be used to make the cylinder liner. These materials are then loaded into a furnace, which heats them to high temperatures until they become molten. Generally, cast iron is melted at temperatures between 1200°C and 1400°C (2192°F to 2552°F) in a furnace, which is hot enough to melt the iron and any other alloying materials that are added to it. The exact melting temperature can also depend on the specific grade of cast iron used, as different grades of cast iron have varying compositions and properties. For example, grey cast iron typically has a lower melting temperature than ductile cast iron, due to its higher carbon content.
In addition to the melting temperature, the casting process also involves controlling the cooling rate of the molten cast iron to ensure that the cylinder liner has the desired properties and characteristics. This can involve using different cooling rates or additives to adjust the microstructure of the cast iron and improve its strength and wear resistance.
At Anand Liners we have five 500 kg medium frequency induction furnaces, our production capacity is 200,000 pcs (950 MT tonnes) per month.
Pouring & Centrifugal Casting
1. Mold preparation: The mold for the cylinder liner is made from a cylindrical steel shell that has a diameter slightly larger than the desired finished diameter of the liner. The inner surface of the shell is coated with a refractory material to prevent the molten metal from sticking to it.
2. Preheating: The mold is then preheated to a specific temperature, typically between 200°C to 300°C (392°F to 572°F), to help prevent the molten cast iron from cooling too rapidly and to promote a better surface finish and micro structure.
3. Pouring: The mold is then rotated at high speeds, usually around 900-1500 rpm, around its horizontal axis while the molten metal with temperature between 1200°C to 1400°C (2192°F to 2552°F),is poured into it through a sprue. The centrifugal force created by the rotation of the mold forces the molten metal to spread evenly along the inner surface of the mold, forming a cylinder shape. Centrifugal force: The centrifugal force created by the rotation of the mold forces the molten metal to spread evenly along the inner surface of the mold. As the mold continues to rotate, the molten metal solidifies and forms a solid cylinder shape with a uniform wall thickness.
4. Solidification: As the mold continues to rotate, the molten metal cools and solidifies, forming a solid cylinder shape. The rotation of the mold ensures that the solidified metal has a uniform thickness along the entire length of the cylinder.
5. Finishing: After the metal has solidified, the mould is stopped and the cylinder liner is removed from the mold. Any excess metal, such as the sprue or gating system, is removed by cutting or machining. The cylinder liner may then undergo further machining processes.
The centrifugal casting process offers several advantages over other casting methods, such as a more uniform distribution of material, reduced porosity, and improved mechanical properties. It is often used in the production of high-quality cylinder liners for various applications such as engines, compressors, and pumps.
Proof Machining
1. Preparing the cylinder liner: The cylinder liner is prepared by cleaning it thoroughly to remove any dirt, debris, or residual coatings using shot blasting machines. The liner is then clamped securely in a fixture or chuck.
2. Rough machining: A roughing tool is used to remove a small amount of material from the surface of the liner, typically around 0.5mm to 1.0mm to prepare it for proof machining. This rough machining step helps to ensure that the liner is symmetrical and centered. The whole Machining process is done using the VTL (SPM) Machines,
3. Measuring the liner: The liner is measured using precision measuring tools such as a micrometer or a dial bore gauge to determine its dimensions and tolerances. The measurements are then compared to the specifications for the cylinder liner to ensure that it meets the required standards.
4. Proof machining: If the measurements are within the desired range, the liner is subjected to proof machining. This process involves removing a small amount of material from the surface of the liner using a cutting tool to achieve the required dimensions and tolerances.
5. Re-measuring the liner: After proof machining, the liner is re-measured using precision tools to ensure that it meets the required specifications. If the measurements are within the desired range, the liner is ready for final machining and finishing.
Proof machining is an important step in the manufacturing of cylinder liners as it helps to ensure that the final product meets the required dimensions and tolerances. By verifying the dimensions before proceeding with final machining, manufacturers can save time and materials by avoiding the need for costly rework.
Fine Boring
Fine boring is a process used to create a precise and accurate cylindrical hole with a smooth surface finish. In the manufacturing of cylinder liners, fine boring is used as a finishing operation to achieve the final dimensions and surface finish of the liner bore.
At Anand Liners fine boring process involves the following steps:
1. Setting up the boring machine: The boring machine is set up with the appropriate cutting tool, boring bar, and workholding fixtures. The machine is also programmed with the desired cutting parameters, such as feed rate, spindle speed, and depth of cut.
2. Preparing the cylinder liner: The cylinder liner is mounted securely in a fixture, and the boring machine is adjusted to ensure that the liner is properly aligned and centered.
3. Rough boring: A rough boring tool is used to remove a small amount of material from the liner bore to create a consistent starting diameter and surface finish. This step helps to ensure that the fine boring tool will produce an accurate and precise bore.
4. Fine boring: A fine boring tool is used to remove a very small amount of material from the liner bore to achieve the final dimensions and surface finish. The fine boring tool typically has multiple cutting edges and is designed to produce a smooth and accurate bore.
5. Measuring the bore: After fine boring, the bore is measured using precision measuring tools such as a dial bore gauge or roundness testing machine to verify that it meets the required specifications.
6. Finishing: If necessary, the bore may undergo additional finishing operations such as honing or grinding to achieve the desired surface finish and dimensional accuracy.
Fine boring is a critical process in the manufacturing of cylinder liners, as it helps to ensure that the liner bore has the precise dimensions and surface finish required for proper function and durability. By using advanced cutting tools and precise machining techniques, manufacturers can produce cylinder liners with excellence.
CNC Final Machining
The final CNC outer diameter process is the last step in the manufacturing of cylinder liners. This process involves using a CNC (Computer Numerical Control) machine to achieve the final outer diameter and surface finish of the cylinder liner.
At Anand Liners CNC process typically involves the following steps:
1. Preparing the cylinder liner: The cylinder liner is cleaned and mounted securely in a collet on the CNC machine. The machine is programmed with the desired cutting parameters, such as feed rate, spindle speed, and depth of cut.
2. Roughing: A roughing tool is used to remove a small amount of material from the outer diameter of the liner to create a consistent starting diameter.
3. Semi-finishing: A semi-finishing tool is used to remove more material and achieve a smoother surface finish.
4. Finishing: A finishing tool is used to remove the final amount of material and achieve the desired surface finish and dimensional accuracy.
5. Measuring the liner: After the CNC outer diameter process is complete, the cylinder liner is measured using precision measuring tools such as a micrometer, contour machine, roughness tester profile projector etc. to ensure that it meets the required specifications.
The CNC outer diameter process is a critical step in the manufacturing of cylinder liners as it helps to ensure that the final product has the precise dimensions and surface finish required for proper function and durability. By using advanced CNC machines and precise cutting tools, we are able to produce cylinder liners with excellent accuracy and surface finish.
Grinding
The final grinding outer diameter for dry cylinder liners is done using a centerless grinding machine. We do grinding using a centerless grinding machine to achieve the final outer diameter and surface finish of the cylinder liner.
At Anand Liners final grinding outer diameter process using centerless grinding typically involves the following steps:
1. Preparing the cylinder liner: The cylinder liner is cleaned and mounted on the centerless grinding machine. The machine is adjusted to ensure that the liner is properly aligned and centered.
2. Rough grinding: A roughing wheel is used to remove a small amount of material from the outer diameter of the liner to create a consistent starting diameter.
3. Finishing: A finishing wheel is used to remove the final amount of material and achieve the desired surface finish and dimensional accuracy.
4. Measuring the liner: After the centerless grinding process is complete, the cylinder liner is measured using precision measuring tools such as a micrometer, roundness tester, roughness tester etc. to ensure that it meets the required specifications.
The final grinding outer diameter process using centerless grinding is a critical step in the manufacturing of dry cylinder liners as it helps to ensure that the final product has the precise dimensions and surface finish required for proper function and durability. By using advanced centerless grinding machines and precise grinding wheels, we are able to produce cylinder liners with excellent accuracy and surface finish.
Plateau Honing
Plateau honing is a precision honing process used in the manufacturing of cylinder liners to achieve a specific surface finish and geometry on the liner’s bore. We bore the liner’s bore using a set of honing stones (Dimond) that are specifically designed for the plateau honing process.
At Anand Liners plateau honing process involves the following steps:
1. Preparing the cylinder liner: The cylinder liner is cleaned and prepared for the honing process. Any burrs or other surface imperfections on the bore surface are removed using a deburring tool.
2. Honing: The honing stones are mounted in a honing head and the liner is passed through the honing head multiple times while rotating to achieve a specific cross-hatch pattern on the bore surface. The cross-hatch pattern is important as it helps to retain oil on the liner surface, which is critical for proper engine lubrication.
3. Plateau honing: Once the honing process is complete, the liner is honed again using a specific set of honing stones to achieve a plateau finish on the bore surface. The plateau finish is a specific type of surface finish that has a plateau-like appearance with tiny peaks and valleys. This surface finish is important as it helps to retain oil on the liner surface and provide the required lubrication.
4. Cleaning and measuring: After the plateau honing process is complete, the cylinder liner is cleaned and inspected to ensure that it meets the required specifications. The bore size, surface finish (roughness), plateau parameters are measured using precision measuring tools such as a bore gauge, roughness tester, Air guage etc.
The plateau honing process is a critical step in the manufacturing of cylinder liners, as it helps to achieve the required surface finish and geometry on the liner’s bore surface. The process is highly precise and requires specialized equipment and skilled operators to ensure that the final product meets the required specifications.
Final Inspection
In final inspection stage we maintain & checked all parameter as per standard drawing. We have Digital micrometers, Digital vernier , Boregauge, Roundnesstester & pneumatic Plug gauge, pneumatic ring gauge which fullfill the final inspection criteria.
Marking
We have Laser marking machine which provide higly accurate and presice marking capability.
Packing
We have seprate packing department in which first liners move through visual inspection & washing. we have Automatic lamination machine for corrogeted boxes,striping machine , dewatring system , rust prevention system through which liner moved & packed in dust preventive room. We use Corrogeted wooden pallet & export wooden box.