University of Engineering and Technology,
Lahore
CIM Lab
CEP By:
Roll # 20
Roll # 32
Roll # 36
Roll # 37
Roll # 38
Department of Automotive Engineering
Contents
Precision Forging Pvt. Ltd ............................................................................................................................. 3
list of parts along with their details. ........................................................................................................... 3
1.
Rocker arms ...................................................................................................................................... 3
2.
Pinion shafts ..................................................................................................................................... 4
3.
Side gears for Fiat tractors ............................................................................................................... 5
4.
Crown wheels ................................................................................................................................... 6
5.
Pinions gear ...................................................................................................................................... 7
6.
Star gears .......................................................................................................................................... 9
7.
Kick Spindle..................................................................................................................................... 12
8.
Ratchet 70 ....................................................................................................................................... 13
9.
Ratchet 125 ..................................................................................................................................... 14
10.
Center clutch............................................................................................................................... 16
11.
pinion kick starter....................................................................................................................... 17
12.
Gear drive ................................................................................................................................... 18
Rank Order Matrix...................................................................................................................................... 20
For this CEP we visited Precision Forging Pvt. Ltd
Following are the list of parts along with their details.
1. Rocker arms
Rocker arms are typically made through a combination of casting, machining, and heat treatment
processes. Here's a brief overview of the manufacturing steps:
Material selection:
The appropriate material for the rocker arm is chosen based on factors like engine requirements,
strength, weight, and cost considerations.




Casting: The chosen material, often an alloy, is melted and poured into a mold with the shape of
the rocker arm. Once the molten material cools and solidifies, the rocker arm is removed from
the mold, and any excess material is trimmed off.
Machining: The cast rocker arm undergoes various machining operations to refine its shape,
dimensions, and surface finish. This may involve processes like milling, drilling, and grinding to
achieve the desired specifications.
Heat treatment: To enhance the rocker arm's mechanical properties, such as hardness and
strength, it may undergo a heat treatment process. Heat treatment involves subjecting the rocker
arm to controlled heating and cooling cycles.
Surface finishing: Surface finishing techniques like polishing or coating may be applied to improve
wear resistance and reduce friction. This helps ensure smooth operation and durability of the
rocker arm.
2. Pinion shafts
Pinion shafts are important components in various mechanical systems, particularly in power
transmission applications. They are typically used to transmit rotational motion and torque between two
meshing gears. Here's a brief overview of how pinion shafts are made and their uses:


Material selection: Pinion shafts are commonly made from high-strength steel alloys that can
withstand the forces and stresses associated with power transmission. The specific alloy chosen
depends on factors such as the application requirements, load capacity, and durability.
Machining: The manufacturing process for pinion shafts often involves machining operations.
Initially, a cylindrical bar or billet of the chosen material is selected. The bar is then mounted on a
lathe or milling machine, where it undergoes various cutting, turning, and drilling operations to
shape it into the desired form of the pinion shaft. This includes creating features such as splines,
keyways, and mounting flanges.



Heat treatment: After machining, the pinion shaft is subjected to a heat treatment process to
enhance its mechanical properties. Heat treatment involves controlled heating and cooling cycles
to improve the shaft's hardness, strength, and durability. This ensures that it can withstand the
loads and stresses it will encounter during operation.
Surface finishing: Depending on the application requirements, the pinion shaft may undergo
surface finishing operations such as grinding or polishing. These processes help achieve the
desired surface finish, accuracy, and dimensional tolerances.
Assembly: Once the pinion shaft is manufactured, it is assembled into the mechanical system
where it will be used. This involves mounting the shaft onto bearings or bushings and ensuring
proper alignment with the mating gears.
Uses of Pinion Shafts:



Power transmission: Pinion shafts are commonly used in gear systems to transmit rotational
motion and torque between meshing gears. They are crucial in various applications, including
automotive transmissions, industrial machinery, and power generation systems.
Steering systems: Pinion shafts are also utilized in steering systems, where they connect the
steering wheel to the rack or steering mechanism. They help convert the rotational motion of the
steering wheel into linear motion to steer the vehicle.
Mechanical clocks and watches: Pinion shafts are employed in the intricate mechanisms of
mechanical clocks and watches to transfer rotational motion and power between different gears,
enabling accurate timekeeping.
3. Side gears for Fiat tractors
The manufacturing process of side gears for Fiat tractors, or any other similar application, typically
involves the following steps:





Material selection: High-strength steel alloys are commonly used for side gears due to their
durability and ability to withstand the forces and stresses involved in power transmission.
Forging: The chosen steel material is heated and subjected to a forging process. This involves
applying compressive force to shape the heated material into the desired form of the side gear.
Forging helps improve the strength and structural integrity of the gear.
Machining: After forging, the side gears undergo machining operations to refine their shape,
dimensions, and surface finish. This includes processes like milling, drilling, and turning to achieve
the required specifications and ensure proper fit with other mating components.
Heat treatment: To further enhance the mechanical properties of the side gears, they undergo a
heat treatment process. This typically involves a combination of heating and cooling cycles to
achieve the desired hardness, strength, and durability.
Surface finishing: Surface finishing techniques like grinding or polishing may be applied to
improve the surface smoothness and reduce friction. This helps ensure smooth operation and
efficient power transmission.
Uses of Side Gears in Fiat Tractors:


Differential mechanism: Side gears are crucial components of the differential system in Fiat
tractors. They are responsible for transmitting torque from the drive shaft to the axle shafts,
allowing each wheel to rotate at different speeds during turns. This enables better
maneuverability and traction control in agricultural applications.
Power transmission: Side gears, along with other gears and components, are part of the power
transmission system in the tractor. They help transmit torque from the engine to the wheels,
enabling the tractor to move and perform various tasks, such as plowing, tilling, and towing.
4. Crown wheels
Crown wheels, also known as ring gears, are crucial components in the differential system of vehicles.
They are responsible for transferring rotational power from the pinion gear to the drive axles. Here's a
brief overview of how crown wheels are made and their uses:


Material selection: Crown wheels are typically made from high-strength steel alloys that can
withstand the forces and stresses involved in power transmission. The specific alloy chosen
depends on factors such as the application requirements, load capacity, and durability.





Casting or forging: The manufacturing process for crown wheels often involves either casting or
forging.
Casting: In casting, the chosen steel alloy is melted and poured into a mold with the shape of the
crown wheel. Once the molten metal cools and solidifies, the crown wheel is removed from the
mold, and any excess material is trimmed off. This process is suitable for producing crown wheels
with intricate designs and complex geometries.
Forging: Forging involves shaping the heated steel alloy by applying compressive force. The
material is heated and placed between two dies, and pressure is applied to deform it into the
shape of the crown wheel. Forging enhances the strength and structural integrity of the crown
wheel.
Machining: After casting or forging, the crown wheel undergoes machining operations to refine
its shape, dimensions, and surface finish. This includes processes like milling, drilling, and grinding
to achieve the required specifications and ensure proper fit with other differential components.
Heat treatment: To enhance the mechanical properties of the crown wheel, it undergoes a heat
treatment process. Heat treatment typically involves controlled heating and cooling cycles to
achieve the desired hardness, strength, and durability.
Uses of Crown Wheels:


Differential system: Crown wheels are integral components of the differential system in vehicles.
They engage with the pinion gear, allowing the rotational power from the engine to be transferred
to the drive axles. The crown wheel's teeth mesh with the pinion gear, enabling torque
distribution to the wheels while allowing for speed differentiation during turns.
Power transmission: Crown wheels, along with the pinion gear and other components, are part
of the power transmission system in vehicles. They help transmit torque from the engine to the
wheels, enabling the vehicle to move and providing the necessary power for acceleration and
towing.
5. Pinions gear
Pinions gear are important components used in various mechanical systems, particularly in gear
mechanisms. They are responsible for transmitting rotational motion and torque between meshing gears.
Here's a brief overview of how pinions are made and their uses:




Material selection: Pinions are typically made from high-strength steel alloys that can withstand
the forces and stresses associated with power transmission. The specific alloy chosen depends on
factors such as the application requirements, load capacity, and durability.
Machining: The manufacturing process for pinions often involves machining operations. A
cylindrical bar or billet of the chosen material is selected and mounted on a lathe or milling
machine. Various cutting, turning, and drilling operations are performed to shape the material
into the desired form of the pinion. This includes creating the gear teeth, keyways, and mounting
features.
Heat treatment: After machining, the pinion is subjected to a heat treatment process to enhance
its mechanical properties. Heat treatment involves controlled heating and cooling cycles to
improve the pinion's hardness, strength, and durability. This ensures that it can withstand the
loads and stresses it will encounter during operation.
Surface finishing: Depending on the application requirements, the pinion may undergo surface
finishing operations such as grinding or polishing. These processes help achieve the desired
surface finish, accuracy, and dimensional tolerances.
Uses of Pinions:

Power transmission: Pinions are commonly used in gear systems to transmit rotational motion
and torque between meshing gears. They play a crucial role in various applications, including
automotive transmissions, industrial machinery, and power generation systems.


Steering systems: Pinions are employed in steering systems, where they are part of the rack and
pinion mechanism. They convert the rotational motion of the steering wheel into linear motion,
allowing the vehicle's wheels to turn and enabling steering control.
Mechanical clocks and watches: Pinions are utilized in the intricate mechanisms of mechanical
clocks and watches. They transfer rotational motion and power between different gears, enabling
accurate timekeeping and the various functions of the timepiece.
6. Star gears
Star gears, also known as spur gears or straight-cut gears, are commonly used in mechanical systems to
transmit rotational motion and torque between parallel shafts. Here's a brief overview of how star gears
are made and their uses:
Further types of gears is


Material selection: Star gears are typically made from high-strength steel alloys or other suitable
materials depending on the application requirements, load capacity, and durability
considerations.
Machining: The manufacturing process for star gears often involves machining operations. A
cylindrical bar or billet of the chosen material is selected and mounted on a lathe or milling
machine. Various cutting, turning, and shaping operations are performed to create the gear teeth
and the overall shape of the star gear. This includes determining the gear module, tooth profile,
and number of teeth.
Heat treatment: After machining, the star gear is subjected to a heat treatment process to
enhance its mechanical properties. Heat treatment involves controlled heating and cooling cycles
to improve the gear's hardness, strength, and durability, ensuring it can withstand the loads and
stresses during operation.

Surface finishing: Depending on the application requirements, the star gear may undergo surface
finishing operations such as grinding or polishing. These processes help achieve the desired
surface finish, accuracy, and dimensional tolerances.
Uses of Star Gears:



Power transmission: Star gears are commonly used in gear systems to transmit rotational motion
and torque between parallel shafts. They are found in various applications such as automotive
transmissions, industrial machinery, and mechanical power transmission systems.
Motion control: Star gears can be used in mechanical systems that require precise motion control,
such as robotics and precision machinery. They enable the synchronized rotation of shafts,
allowing for accurate positioning and movement control.
Gear reduction: Star gears can be part of gear reduction systems, where they provide different
gear ratios to adjust the speed and torque output between input and output shafts. This is often
seen in applications such as speed reducers and gearboxes.
7. Kick Spindle
A kick spindle, also known as a great wheel or wool wheel, is a type of spinning wheel used for hand
spinning fibers into yarn. It is a simple and portable spinning tool. Here's a brief overview of how a kick
spindle is made and its uses:

Base construction: The kick spindle starts with the construction of a sturdy base. This is typically
made of wood and consists of a horizontal platform or table with legs for stability.



Spindle assembly: The spindle, which is the central component of the kick spindle, is constructed
next. It consists of a rod or dowel that extends vertically from the base. At the top of the spindle,
a round whorl or disc is attached. The whorl helps maintain momentum and control the speed of
the spindle.
Drive wheel assembly: A large drive wheel is attached horizontally to one end of the base. The
drive wheel is typically made of wood and features a groove or rim that connects to a drive band.
Treadle and kick mechanism: A treadle, which is a foot-operated lever, is connected to the base
near the drive wheel. The spinner uses their foot to kick or push the treadle, which rotates the
drive wheel. The movement of the drive wheel imparts rotational motion to the spindle, causing
the fibers to be spun into yarn.
Uses of a Kick Spindle:



Hand spinning: The main use of a kick spindle is for hand spinning fibers into yarn. The spinner
places fibers on the spindle, starts the rotation by kicking the treadle, and uses their hand to draft
and twist the fibers into yarn as the spindle spins.
Portability and convenience: Kick spindles are portable and lightweight compared to larger
spinning wheels. They can be easily moved and set up in different locations, making them
convenient for spinning yarn while traveling or in limited space.
Learning and hobby spinning: Kick spindles are often used by beginners learning to spin yarn by
hand. They offer a simple and accessible spinning method that allows individuals to develop their
spinning skills and create their own yarn.
8. Ratchet 70
A ratchet is a mechanical tool that allows for unidirectional motion. It typically consists of a handle, a gear
mechanism, and a pawl. Here's a general overview of how a ratchet is made and its uses
Manufacturing Process:





Material selection: Ratchets are commonly made from durable and high-strength materials such
as steel or alloy. The specific grade and type of material may vary based on the intended use and
desired strength.
Machining: The manufacturing process for a ratchet involves various machining operations. This
includes milling, turning, and drilling to shape the handle, gear mechanism, and pawl. Precision
machining is crucial to ensure proper functionality and smooth operation.
Gear mechanism: The gear mechanism of a ratchet consists of a series of teeth that are cut into a
gear or wheel. The gear is usually made separately and then assembled onto the handle. The teeth
are precisely spaced to allow for smooth movement in one direction and prevent backward
motion.
Pawl assembly: The pawl is a small metal component that engages with the gear teeth. It is
typically spring-loaded to ensure proper engagement and to prevent unintentional movement.
The pawl is usually made separately and assembled onto the ratchet mechanism.
Surface finishing: After machining, the ratchet undergoes surface finishing processes to improve
its appearance and functionality. This may include processes like grinding, polishing, or coating to
enhance durability, corrosion resistance, and aesthetics.
Uses of a Ratchet:




Socket wrench: One of the most common uses of a ratchet is in combination with sockets for
turning nuts and bolts. The ratchet allows for easy and efficient tightening or loosening of
fasteners in confined spaces.
Torque control: Ratchets are often used in applications where controlled torque is necessary. The
unidirectional motion of the ratchet ensures that torque is applied in the desired direction
without accidental backward movement.
Automotive and mechanical repairs: Ratchets are extensively used in automotive and mechanical
repairs for tasks such as engine work, suspension maintenance, and general mechanical tasks.
Construction and building: Ratchets find application in construction and building projects for
tasks such as assembling furniture, tightening bolts, or securing structures.
9. Ratchet 125
A ratchet is a mechanical tool that allows for unidirectional motion. It typically consists of a handle, a
gear mechanism, and a pawl. Here's a general overview of how a ratchet is made and its uses:
Manufacturing Process:
Material selection: Ratchets are commonly made from durable and high-strength materials such as
steel or alloy. The specific grade and type of material may vary based on the intended use and desired
strength.




Machining: The manufacturing process for a ratchet involves various machining operations.
This includes milling, turning, and drilling to shape the handle, gear mechanism, and pawl.
Precision machining is crucial to ensure proper functionality and smooth operation.
Gear mechanism: The gear mechanism of a ratchet consists of a series of teeth that are cut
into a gear or wheel. The gear is usually made separately and then assembled onto the handle.
The teeth are precisely spaced to allow for smooth movement in one direction and prevent
backward motion.
Pawl assembly: The pawl is a small metal component that engages with the gear teeth. It is
typically spring-loaded to ensure proper engagement and to prevent unintentional
movement. The pawl is usually made separately and assembled onto the ratchet mechanism.
Surface finishing: After machining, the ratchet undergoes surface finishing processes to
improve its appearance and functionality. This may include processes like grinding, polishing,
or coating to enhance durability, corrosion resistance, and aesthetics.
Uses of a Ratchet:

Socket wrench: One of the most common uses of a ratchet is in combination with sockets for
turning nuts and bolts. The ratchet allows for easy and efficient tightening or loosening of
fasteners in confined spaces.



Torque control: Ratchets are often used in applications where controlled torque is necessary.
The unidirectional motion of the ratchet ensures that torque is applied in the desired direction
without accidental backward movement.
Automotive and mechanical repairs: Ratchets are extensively used in automotive and
mechanical repairs for tasks such as engine work, suspension maintenance, and general
mechanical tasks.
Construction and building: Ratchets find application in construction and building projects for
tasks such as assembling furniture, tightening bolts, or securing structures.
10. Center clutch
A center clutch, also known as a centrifugal clutch, is a type of mechanical clutch that is used in various
applications to engage and disengage power transmission. Here's a brief overview of how a center clutch
is made and its uses:
Manufacturing Process:



Housing: The clutch assembly begins with the construction of a housing or casing, which contains
the clutch components. The housing is typically made of metal, such as aluminum or steel, and is
machined to precise specifications.
Clutch Drum: The clutch drum is a key component of the center clutch. It is usually made of steel
and consists of a cylindrical drum shape with internal splines or teeth. The drum is machined or
formed to accommodate the clutch components.
Clutch Shoes: The clutch shoes are typically made of metal or composite materials with friction
linings. These shoes are designed to engage with the clutch drum when rotational speed
increases. The shoes may be riveted or bonded to metal carriers, and they are often adjustable to
control the engagement characteristics of the clutch.

Springs: Springs are used to provide the necessary force to keep the clutch shoes disengaged at
lower speeds. These springs are carefully selected and installed in the clutch assembly to achieve
the desired engagement and disengagement characteristics.
Uses of a Center Clutch:



Power Transmission: Center clutches are commonly used in small engine applications, such as
lawnmowers, go-karts, and small vehicles. They allow for the efficient transmission of power from
the engine to the driven wheels or other driven components.
Automatic Clutching: Center clutches are often used in applications where automatic
engagement and disengagement of power transmission is desired. As the rotational speed of the
engine increases, the centrifugal force causes the clutch shoes to engage with the clutch drum,
transferring power. When the engine speed decreases, the clutch shoes disengage, allowing for
smooth operation and idle mode.
Safety Features: Center clutches can provide safety features by automatically disengaging the
power transmission when the engine is idling or at rest. This prevents unintended movement or
engagement of driven components and improves overall safety.
11. pinion kick starter
A pinion kick starter is a component used in internal combustion engines to initiate the engine's starting
process. Here's a brief overview of how a pinion kick starter is made and its uses:
Manufacturing Process:

Material selection: Pinion kick starters are typically made from durable and strong materials, such
as steel or alloy. The specific grade and type of material may vary based on the manufacturer's
specifications and requirements.



Machining: The manufacturing process involves machining operations to shape and form the
pinion kick starter. This includes cutting, milling, and shaping the components to achieve the
desired dimensions and functionality.
Gear Teeth: The pinion kick starter features gear teeth that engage with the engine's starting gear
or flywheel. The gear teeth are carefully cut or machined to ensure proper meshing and
transmission of rotational force.
Assembly: The pinion kick starter is assembled with other components such as bearings, bushings,
springs, and mounting brackets. These components ensure smooth operation, proper
engagement, and secure installation.
Uses of a Pinion Kick Starter:




Engine Starting: The primary use of a pinion kick starter is to initiate the starting process of an
internal combustion engine. When the rider or operator kicks down on the kick starter lever, the
pinion engages with the engine's starting gear or flywheel, turning the crankshaft and initiating
the engine's firing sequence.
Manual Start System: Pinion kick starters are commonly used in motorcycles, dirt bikes, and other
small engine applications where manual starting is required. They provide a convenient and
reliable method for starting the engine without relying on electric starters.
Backup Starting System: In some applications, a pinion kick starter can serve as a backup starting
system in case of electrical system failures or battery discharge. It allows the engine to be started
even when the electric starter is unavailable or not functioning.
Lightweight and Compact: Pinion kick starters are designed to be lightweight and compact,
making them suitable for various small engine applications where space and weight are crucial
considerations.
12. Gear drive
Gear drive is used, when centre to centre distance between driver and driven shafts is very small. Gears
are defined as, "toothed wheels, which can transmit power and motion from one shaft to another shaft
by means of successive engagement of teeth.
It is important to note that, both the gears, which are engaged, always rotate in opposite direction. Gear
drive consists of two wheels. The smaller wheel is called as pinion and the larger wheel is called as gear.
Refer. In gear drive, slip is absent. Therefore, it gives exact and uniform velocity ratio. Due to this ability
of maximum power transmission and exact velocity ratio, gear drive is called as perfect positive drie.
Advantages of Gear Drive
1. Exact velocity ratio.
2. High efficiency.
3. Compact layout.
4. Ability of transmitting large power.
5. Reliable service.
Disadvantages of Gear Drive
1. Manufacturing of gears requires special tools and equipment. This leads to high production cost.
2. Complicated manufacturing process. 3. Gear drive requires precise alignment of shafts.
4. Costly lubrication system is required for smooth operation and longer life of gear teeth.
Rank Order Matrix
We arranged the parts according to similarities in shape and geometry and the processes used to make
them:
Machin
es
217
R.
A
216
P.S
215 214
213 212 211 210
S.G C.
CDM CD P.G S.G
W
2
M4
Shaper
1
Drill
machine
1
grinding
1
1
Milling
Lath
1
1
1
1
1
1
1
1
1
1
28 27
26
25
24
23 22 21
R.7 R. P.K C.C CD G.C C
CG
0
12 .S
C3 .I
G M4
5
M
3
1
1
1
1
1
1
1
1
1
1
1
1
Casting
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
20
CC
1
1
1
1
Cutter
Gear
broacher
CNC
1
29
K.
S
1
1
1