Machine Shop

Their are mainly two types of machine of are present i.e., CNC and
VMC.

CNC(computer numeric control):-

 CNC machine is the automation of m/c tools that are
operated by precisely programmed commands encoded
on a storage medium as opposed to controlled manually
by hand wheel or levers or mechanically automated by
cams alone.

 In modern CNC system end to end component designed

is highly automated using cad and cam programs.

 The program produce a computer file i.e. interpreted

extract the commends needed to operate a particular
machine by use post processer.

 Examples of CNC machines are:-

 Two types of CNC machine are used at Yamaha motors.

 MILLS:- CNC mills use computer controls to cut different

materials. They are able to translate programs consist of
specific numbers and letters to move the spindle or
 workpiece to various locations and depths.

 Lathes :- lathes are machines that cut workpiece while

they are rotated. CNC lathes are able to make fast
precision cuts generally using indexable tools and drills

VMC (Vertical machine center) :-

 A vertical machining center is a machining center with its spindle
in vertical orientation.

 High end VMC are high precisions machines often used for tight
tolerance milling, such as fine die and mold work.
 Engine parts

These following engine parts are machined

by Yamaha motors:-

1. Head cylinder

2. Body cylinder

3. Crank

4. Cam shaft

5. Connecting rod

6. Axle

7. Gear

8. Crank case
Head cylinder
Introduction:-

 In an internal combustion engine the cylinder head sits

above the cylinders on top of cylinder block.

 It closes in the top of the cylinder forming the combustion

chamber this joint is shield by a head gasket.

 In most of engine the head also provides space for the

passage that feed air and fuel to the cylinder and that allow
the exhaust to escape.

 Internally the cylinder head has passages called ports of

tracts for the fuel air mixture to travels to the inlet valve
from the intake manifold and for exhaust gases to travel
from the exhaust valves to the exhaust manifold.

 The cylinder head contains the valves the spark plugs and
inlet exhaust tracts just like the overhead valve engine but
the cam shaft is now also contained within the cylinder
head.
 The design of the cylinder head is the key to the
performance and efficiency of the internal combustion
engine as the shape of the combustion chamber, inlet
passages and ports determines a major portion of the
volumetric efficiency and compression ratio of the engine.

Operations:-
 Mainly these operations are performed on the cylinder head
-

1. Casting

2. Face milling

3. Spot facing

4. Drilling

5. Rough/Fine boring

6. Tapping

7. Chamfering

8. End milling

9. Oil removing

10. Leakage testing

11. Marking
 12. Inspection

 In the Yamaha motors various type of models are to be

machined

 Model name:- 54B - Used in 2 valve bike .

2FD-Used in R15 and other sports bike

 Selection of material :- The choice of material for engine

structure is much more involved then considering strength
and weight.

 Cylinder head and blocks are highly and dynamically loaded

the structure that transfer a lot of heat.

 Things that must be consider include material cost, specific

weight, strength, ductility, fatigue life, thermal expansion,
thermal conductivity, cast ability, mold sticking, machine
ability, processing cycle time, required tooling, corrosion
resistance.
Body cylinder
Introduction:-
 A cylinder block is an integrated structure comprising the
of a reciprocating engine and often some or all of their
associated surrounding structures.

 The term engine block is often used synonymously with

cylinder block.

 In the basic terms of machine elements, the various main

parts of an engine are conceptually distinct, and these
concept an all be instantiated as discrete pieces that are
bolted together.

 The construction of the cylinder block was very wide

spread in the early decades of the commercialization of
internal combustion engine and it is still sometimes used
in certain application where it remains advantageous.

 However, it is no longer the normal way of building most

petrol engine.

 function of the cylinder block is that it is separated with

head cylinder at the lower side and at the lower side the
crank is connect with conn. Rod and piston is moving
inside body cylinder from TDC to BDC .

 There is a two type of volume in the cylinder i.e.

clearance volume and swept volume
 In the body cylinder the grade are designed according to
the bore diameter

 Grade A-0.05mm

Grade B-0.10mm

Operations:-
 Mainly these operations are performed on the body
cylinder-

1. Casting

2. Face milling

3. Center drilling

4. Chamfering

5. Rough/fine boring

6. Honing

7. Oil removing

8. Washing
 9. Leakage testing

10. Marking

11. Packing

 In the body cylinder when the piston in moving then the

port and valve is open accordingly their stroke

 In 2-stroke engine having port.

4-stroke engine having valve.

 Selection of material:-it is generally cast from either a

suitable grade of iron or an aluminum alloy.

 The aluminum block is much lighter in weight and has

better heat transfer to the coolant, but iron block retain
some advantages and continue to be used by some
manufacturer.

 Because of the use of cylinder liners and bearing shell,

the relative softness of aluminum is of no consequence.

 Light duty consumer grade use a mono block design

where the cylinder head, block and half the crank case
save the same casting.

Crank
Introduction:-
 The crank is mechanical able to perform a conversion
between reciprocating motion and rotational motion In a
reciprocating engine, it translate reciprocating motion of
piston into rotational motion; whereas in a reciprocating
compressor.

 In order to do the conversion between two motions ,the

crank shaft has crank throws or crank pins ,additional
bearing surface whose axis is offset from the of the crank
to which the big ends of the connecting rods each cylinder
attach.

 It is typically connected to flywheel to reduce the pulsation

characteristics of four stroke cycle and sometimes a
torsional or vibrational damper at the opposite end to
reduce the torsional vibration often caused along the length
of the crankshaft by the cylinders farthest from the output
and acting on the torsional elasticity of the metal.

Machining:
 It can also be machined out of a billet, often a bar of high
quality vacuum re-melted steel.

 Through the fiber flow doesn’t follow the shape of a crank

 shaft, this usually not a problem since higher quality steel,
which normally are difficult to forge.

 These crankshaft tend to very expensive due to large

amount of material that must be removed with lathes and
milling machines, the high material cost, and additional heat
treatment required.

 Machining or remanufacturing crankshaft are precision

machined to exact tolerance with no odd size crank shaft
bearings or journals.

 Thrust surface are micro-polished to provide pre-size

surface finishes for smooth engine operation and reduced
thrust bearing wear.

Operations:-
 Mainly these operations are performed on the crank-

1. Forging

2. Center facing

3. Rough/fine turning

4. Eccentric boring

5. Keyway cutting

6. Hardening

7. Thrust facing

8. ID grinding
 9. Grading

10. Etching

 Models name:-

Old models-5KAE-crank-2

5TS-crank-1

4LS-crank-1, 2

5YY-crank-1, 2

New models-21C-crank-1, 2(used in bikes)

2GS- crank-1, 2

1GC- crank-1, 2(used in

scooter)

Cam shaft
Introduction:
 A camshaft is a shaft to which cam is fastened or of which
a cam forms an integral part.

 In other word can say cam shaft is a type of shaft that is

used for determined the movement of the valve.

 The key [arts of the any camshaft are the lobes, as the
camshaft spins, the lobes open and close the intake and
exhaust valve in time with the motion of the piston.

 It turns out that there is a direct relationship between the

shape of the cam lobes and the way the engine performs in
different speed ranges.

 Modern engine is designed the (overhead valve engine) are

driven by the two camshafts per cylinder bank arrangement
i.e. one camshaft for intake valve and another for exhaust
valve.

 In internal combustion engine with pistons, the camshafts is

used to operate poppets valves.

 It then consists of a cylinder bank with the numbers of

oblong lobes protruding from it, one for each valve the cam
lobes force the valves open by pressing on the valve or on
some intermediate mechanism as they repeat.

 The timing of the camshaft can be advanced to produce

better low rpm torque, or retarded for better high rpm
power.
 Either, of these moves the overall power produced by the
engine down or up the rpm scale respectively. The amount
of change is very little.

Operations:-
 Mainly these operations are performed on the cam shaft-

1. Casting

2. Center drilling

3. Facing

4. Turning

5. Drilling

6. Tapping

7. Keyway

8. Oil hole drilling

9. Inspection

10. Packing for dispatch

 Models name:-

old models-5TS
 34C(change in face angle)

5KA(diff. grove)

4LS

5YY(high length)

New models-21GC(used in R15)

 Tool material for cam shaft is high speed steel.

 The mainly two portion have on camshaft i.e. free portion or

face angle portion.

 Dimensions with their tolerences:-

1. C.depth-6.25+0.05mm

2. Dimn.-75.7/0.0/0.1

3. Dimn.-31.8

4. Runout-3.0

 Material selection-camshafts can be made out of several

type of material. these include-

 chilled iron casting: commonly used in high volume

production chilled iron cam shaft have a good wear
resistance since the chilling process hardens them.

 Other element are added to the iron before casting to

make the material more suitable for its application.
 Billet steel: when a high quality camshaft or low volume
production is required engine builders and camshafts
manufacturers choose steel billets this is much more time
consuming and expensive then other method.

Connecting rod
Introduction:
 In a reciprocating engine, the connecting rod or con rod
connects he piston to the crank or crankshaft.

 Together with the crank they forms a simple mechanism

that converts reciprocating motion into rotating motion.

 Connecting rod may also converts rotating motion into

reciprocating motion.

 As a connecting rod is rigid ,it may transmit either a push

or apull and so the rod may rotate the crank through both
halves of a revolution, i.e. piston pushing or piston pulling.

 Earlier mechanism, such as chains, could only pull, in a

few two stroke engines, the connecting rod is required to
push.

 The small end attached to the piston pin, gudgeon pin or

wrist pin, which is currently most often press fit into con
rod but can swivel in the piston, a floating wrist pin
designed.

 The big end connects to the bearing journal on the crank

throw, in most engine running on replaceable bearing
shells accessible via he connecting rod bolts which the
hold bearing cap onto the bearing ends.

 Typically there is a pinhole bored through the bearing and

the big ends of the connecting rod so that pressurized
motor oil squirts out onto the thrust side of the cylinder wall
to lubricate the travel of the piston and piston rings.
 Operations:
 Mainly these operations are performed on the connecting
rod-

1. Forging

2. Facing

3. S.E.I.D drilling

4. S.E.I.D chamfering

5. B.E.I.D boring

6. Oil hole drilling

7. Heat treatment

8. Surface grinding

9. B.E.I.D grinding

10.S.E.I.D grinding

11. B.E/S.E honing

12.Washing

13.Testing for bend/twist/grinding

14.Inspection

15.Packing for dispatch

 Heat treatment applied on the temperature 500°c on the

 Nippon induction machine.

 These are the main reason to occurs a defects in the

conrod-

1. Grinding oversize

2. Tool failure

3. Power failure

 Heat treatment processes is depends on the torque.

 Material selection: in modern automotive combustion

engines, the connecting rod are most usually made of steel
for production engines, but can be made of T6-2024 and
T651-7075 aluminum alloys or titanium for high
performance engine.

 But generally cast iron is used for motor scooters, they are
not rigidly fix at either end, so that the angle between the
connecting rods, especially in racing bikes engines, they
are being casted or forged.