The document discusses the manufacturing process for an aluminum alloy piston. It begins by describing what a piston is and its functions in engines and pumps. It then discusses the key components of a piston engine. The document goes on to state the objective is to minimize cost while maximizing safety when manufacturing a piston that weighs 0.8-1kg and is 4-6mm in size out of an aluminum alloy for runs of either 1000 or 10000 pieces. It considers investment casting, forging, powder methods, and conventional machining as potential shaping processes and provides a cost comparison of the top three options.

1. Manufacturing process for analuminum alloy pistonGroup 5Eugene Oo

2. What is a piston?Component of engines, reciprocating pumps, gas compressors and pneumatic cylinders.Moving component contained by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod.In a pump, the function is reversed and force is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder

3. Components of a typical, four stroke cycle, DOHC piston engine. (E) Exhaust camshaft, (I) Intake camshaft, (S) Spark plug, (V) Valves, (P) Piston, (R)Connecting rod, (C) Crankshaft, (W) Water jacket for coolant flow.http://www.animatedpiston.com/BMW.htm

4. So how and what?Function- PistonObjective- Minimize Cost(priority) + Maximize SafetyConstraints- Al Alloy, 0.8-1kg,4-6mm,3D, 0.5mm, 5um, 1000 or 10000 piecesVariable- Shaping process

5. For Al alloy

6. 0.8-1kg

7. 4-6mm

8. 3D

9. 0.5mm

10. 5um

11. 1000 or 10000 pieces

12. What is Left?Investment Casting -1000Forging -BothPowder Methods -10,000Conventional Machining -Both

13. COSTS $$$

14. Cost Comparison

15. Between the 3

16. Thank You 