Question

An oil pan used in an engine acts as a reservoir for the engine oil in a car. The design. specifications, require a material with minimum tensile strength of 54 MPa\and a hardness of at least 85 HB (brinell hardness). Additional consideration should be given to, weight minimization (because of the requirement to reduce engine total weight), corrosion resistance (due to extreme weather condition), machinability (to achieve net shape for assembly), and appearance. Based on the size and shape of the product, list several methods that could be used to produce the component. For each method, briefly compare the relative pros and cons, What types of engineering materials might be able on to meet the requirements? State what are the materials that relevant. What would be the pros and cons, casting.

i already chose the material, you can just write about Aluminium

Answer 1

Oil pan of an engine is the storage tank of the oil when not in running condition. The temperature of the oil usually went up to 260-degree celsius. But in the case of racing cars, these values might go up to 500-degree celsius. Oil pans are usually produced through the stamping process.

1. Annealed sheet undergoes cold stamping, where a die is used to make the sheet into the shape of the oil pan.

Pros - Strain hardening of the material, Fast method.

Cons - Introduction of residual stress in the material, Chances of drawing wrinkles

2. Depending on depth required deep drawing also can be used.

Pros - Strain hardening of the material, Fast method

Cons - Drawing wrinkles formation chances are high, High residual stresses

3. Die casting. Aluminium can be formed into the oil pan

Pros - High dimensional accuracy, Strength

Cons - Not applicable high melting point metals and alloys, Expensive, Long process time. Porosity issues

4. Plastic injection moulding. - Polymers like polyamides.

Pros - Easy process, Low cost

Cons - Modification may be laborious, Long process time

5. Recent technology development also suggests the use of additive manufacturing for sports cars.

Pros - High mechanical properties, No drawing wrinkle formation

Cons - Slow method of production, Thermal residual stresses, Expensive.

Aluminium is the best-used material for a specific purpose. Since it has tensile strength up to 310 MPa and has an average hardness of 95 BH. Aluminium also resist corrosion by the formation of the oxide layer. Aluminium is a machinable material also. Aluminium is the suitable materials for stamping process.

Steel is a considerable material where more ductility is required as steel is more ductile than aluminium. Machinability of the steel can be increased by reducing carbon content and increasing chromium and molybdenum. Since corrosion resistance is required chromium and nickel should be high. Steel also possess high strength and hardness.

Polyamides are used for oil pans which produced through plastic injection moulding.

The casting of oil pans may lead to porosity issues due to entrapment of gases. Machining of the casted oil pan is difficult as its complex shape.