Abstract
The present work describes the manufacture of a piston head of 50 mm diameter using aluminium sheet metal. Initially, the service conditions of the existing piston head were used to establish benchmarks of stresses and temperatures as performance criteria for the sheet metal piston head. The piston was re-designed for manufacture using sheet metal. Deep drawing, redrawing, ironing, punching and hole flanging are the major operations. Specially designed tools have been used to make the drawn and ironed cups, and a pair of diametrically opposite flanged holes in the cylindrical surface. The work brings out the process development to facilitate the manufacture of the sheet metal piston head.
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