Summary
Toolcraft, a renowned provider of precision manufacturing solutions, manufactured a high-performance Piston Ring Tool for an auto parts supplier. This tool is engineered to ensure the accurate installation of piston rings in turbocharger assemblies, enhancing machining precision and efficiency in automotive applications. This case study details the specifications, applications, manufacturing process, and quality control measures undertaken to deliver this specialized tooling system.
Project Overview
Product: Piston Ring Tool
Industry: Automotive
Overall Specifications
- Material: S-7 Tool Steel
- Stock Dimensions: 3/4″ Diameter x 2-1/8″ length
- Tolerance: Maintained within +/- .001″
- Surface Finish: 16 µ” AA tapered outside diameter and knurled handle
- Heat Treatment: Vacuum Hardened to Rockwell C 55-57
- Finish: Polished outside diameter
Uses and Applications
The Piston Ring Tool is designed for various automotive assembly tasks, including:
- Turbocharger Assembly: Ensures precise installation of piston rings in turbochargers, critical for high-performance engines.
- Engine Component Assembly: Facilitates accurate and efficient assembly of other intricate engine components.
- High-Volume Production: Suitable for large-scale production runs while maintaining consistent quality.
Capacity
The Piston Ring Tool is designed for exceptional performance on specific assembly applications. While not universally adaptable, each tool is meticulously engineered to meet the unique requirements of its designated assembly. This focus on specialization allows the tool to deliver:
- Optimal Efficiency: Precise design ensures the tool perfectly complements the assembly process, maximizing efficiency and minimizing wasted time or effort.
- Reduced Wear and Tear: The robust build quality ensures the tool can withstand demanding production environments without succumbing to wear and tear, leading to extended service life.
- Enhanced Productivity: By optimizing the assembly process and minimizing downtime, the Piston Ring Tool directly contributes to increased productivity.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Piston Ring Tool met stringent performance and reliability standards:
- Dimensional Inspection: Precision measuring instruments were used to verify all critical dimensions and tolerances.
- Hardness Testing: Hardness tests were conducted to confirm the Piston Ring Tool’s durability and wear resistance.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Piston Ring Tool before delivery to the client.
Quality Control
Toolcraft’s comprehensive quality control procedures ensured the Brass Die scraper met stringent performance and reliability standards:
- Dimensional Inspection: Coordinate Measuring Machines (CMM) were used to verify all critical dimensions and tolerances.
- Material Testing: Metallurgical tests were conducted to confirm the material’s properties and compliance with specifications.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and magnetic particle inspection were employed to detect any internal or surface defects.
- Functional Testing: The assembled Brass Die scraper underwent rigorous functional tests to ensure proper operation and integration with Michelin’s manufacturing process.
- Final Inspection: A thorough final inspection was performed to validate the overall quality and readiness of the Brass Die Scraper before delivery to Michelin.
Manufacturing Process
Design & Engineering
Toolcraft’s production team collaborated closely with the client to understand specific requirements. Advanced CAD software was used to design the Piston Ring Tool, ensuring compatibility with the assembly processes and optimization for the intended tasks.
Material Selection & Procurement
High-grade tool steel was chosen for its durability and wear resistance. Materials were sourced from certified suppliers to ensure quality and consistency.
Precision Machining
Utilizing Toolcraft’s state-of-the-art CNC machining capabilities, the Piston Ring Tool components were manufactured with tight tolerances to ensure precise fit and function. Multi-axis machining centers were employed to achieve complex geometries and features.
Heat Treatment
The Piston Ring Tool underwent hardening and tempering processes to enhance strength and durability.
Surface Finishing
A PVD coating was applied to protect the Piston Ring Tool from wear and corrosion, extending its operational life in demanding automotive environments.
Conclusion
Toolcraft’s expertise in precision manufacturing and commitment to quality enabled the successful development of a high-performance Piston Ring Tool. This specialized tool enhances the capabilities of automotive assembly operations, providing reliable and efficient solutions for a wide range of applications. Through meticulous design, manufacturing, and quality control processes, Toolcraft ensured the delivery of a robust and versatile tooling solution tailored to meet the specific needs of their client.