V .J .T.

I, MATUNGA INPLANT TRAINING REPORT

ASSIGNMENT NO: 03

DESIGN AND FABRICATION OF PULLER

FOR
VALVE SEAT.

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Design and fabrication of puller: -

Need for puller: -

Exhaust valve
position Cylinder head
of Engine

Valve seat to be
Intake valve
remove
position

During the periodic overhauling of the engine when the top overhauling
takes place all the cylinder heads are disassembled. The time for cylinder head
overhauling is 1yr to 1½yr the following table show the standard interval for
disassembling and cleaning: -

Running Hours
Inspection section Work involved
1250 Hr 2500 Hr
Nozzle Injection state inspected ●
Exhaust valve Polishing ●
Intake valve Ditto ●
Starting valve Ditto ●
Cylinder safety valve Ditto ●
Valve spring Outlook inspected ●

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There are 12 intake valve seats which are forcibly attach on the combustion
side of the cylinder head. Press fitted to the head of the cylinder of the engine.
There are two valve seats for each cylinder head both for intake valve. And the
valve seat of the exhaust valve and the body of exhaust valve is the single body.
These intake valve seats are removing during the overhauling.
The main purpose of the valve seat is preventing leakage in between the valve
and body of head during the compression, power and exhaust stroke. It works as
the washer in between the body of head and valve. The design of valve and valve
seat is made such that if they engage with each other they work as a single part.
The valve seat is made up of special cast and the cylinder head is made up of
high grade cast iron of sufficient strength. As they are press fitted with each other
and remains in contact during operation. During the working high temperature and
presence of carbon rusted from inside in gap between head and seat made the
contact rigid and power full.
The old process for removing the valve seat is by hammer and rod. As shown
in fig. But in this case the valve seat is totally damage and we can not reuse that as
its edges are get damage due to the hammering action. And also the formation of
burr take place due to which the problem arise in assembling the valve again. It
may possible that at the end ring get through out with speed and harm any
workman standing near. Also there is the possibility of slip of hammer and injure
the workman.
The traditional way of removing the valve seat is by rod and hammer due to which
both seat and head of the engine would get damage by getting some sharp cuts. So
there was a need to deign a puller which can pull out the seat without causing any
defect to workman, seat, and cylinder head.

Old process
Of
Removing
Seat.

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Seat after
removed.

Rod use
for removing
Hammer seat.

The main concept for design of puller: -

i) The trouble shouting during the study of engine and seeing

defect in previous process.
ii) Study of engine as well as head in deep.
iii) The overall structure and dimension of seat.
iv) The overall structure of head and rough dimension.

v) The material of valve seat (special cast).

vi) Area available around the valve seat for supporting the puller.
vii) The force required to pull the seat out.
viii) Total number of valve seat.

ix) Area for holding the seat and pulling up.

x) Area of contact between puller plate and valve seat.

Main concept for Designing of puller: -

The main task or the main challenge is that I have only 1mm contact with
the valve seat in circular form between the diameter of 89mm of the valve seat and
90mm diameter of the hole which is on cylinder head for intake valve. The holes
actually counter board with height as that of height of valve seat.

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This was the main part where I had to establish a concept which should not
fail. Because once selected two precious thing time and money get invested for
further activities like designing and manufacturing that concept so I had to be very
perfect and have to apply my engineering knowledge. I found out following thing
very important for the puller to be effective.

i) How to pull seat out of the frame.

ii)How to make maximum grip on the puller with the seat as the position which

could be used for gripping was 1mm around circular surface which was
available only after passing through a 89mm diameter and 25mm deep center
hole of the seat or intake valve.
iii) How to get the support so that it can withstand the force
applied for pulling the seat. Along the circumference of the seat the following
part are present as shown in table:-

Distance From Inner Edge Of Part present

Seat.
41 mm Outer edge of the head.
15 mm Intake valve hole.
32 mm Exhaust valve hole.
23 mm Starting valve hole.
26 mm Injector hole.

I started collecting data from visual study also the different concepts form my
colleague and workers. I receive about 4 to 5 ideas and the final concept selected
for designing the puller is as follows: -

i)
The concept to pull the seat out of the cylinder head is by the Newton’s
rd
3 low of motion. By means of nut and bolt arrangement, where 4 nut are provided
with required supports is turned with the help of the spanner it get rotate around

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the bolt with which the bottom body is fixed and that move upward with valve
seat.
ii) The required support is provided with the help of cylindrical structure
which is closed from one side and having slot to see whether seat is coming out or
not. Also it have hole at top to get stud out. The closed side of cylinder is think in
up to withstand against pulling force. Cylinder is taken instead of three leg so as to
get maximum contact as well as good amount of force.
iii) The seat is gripped to the main body by means of the split plate.
iv) Main bottom body has the four bolt welded, on which the step is also
provided for maintaining the split plate out.
v) The split plate is on the bottom body which gets in contact when move
down and split around the step made on bottom body keep it in contact with seat
and not allow it to come in center. After that the middle or split plate made 1mm
circular contact with the valve seat.
vi) Then the upper plate is tightening by means of the nut that make the
three plates as a single one.
vii) Then the main body is insert and it rest on surface then the nut is

tightening so that the bolts pull three plates along with the valve seat.

Selection of material: -

The different part of the puller and selection of material according to their
function are as follows: -

1. Base plate: -
This must withstand the allowable stress that product during pulling action.
This may lead to bend while removing the seat. This must absorb tensile stress as
well as bending stress developed by applied force.

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Material used: - Mild Steel.

2. Split plate: -
This is the part from which maximum force must be transmitted to the
valve seat to get it out of position. As only outer circular edge of 1mm come in
contact. That part of plat may be bend or shear due to the minimum contact
surface and maximum force. This plate also tries to lift upward at the middle part
and come out freely so there is the need of third plate.

Material used: - EN-8 (and good harden).

3. Upper plate: -
The main aim of this plate is to prevent the split plate to come out and also
to tighten the nut the three plates work as a single part.

Material used: -Mild steel.

4. Cylindrical boule: -
This is the main part on which total force come on in opposite direction that
is downward direction. The boule has two slots which can get the idea about the
moment inside the boule whether the seat comes out or not. The outside close part
must be of good strength. That must not get bend due to pulling force.

Material used: -Mild steel.

5. Bolt: -
There are four bolt used in the design. This must have in up strength to pull
the four part out of the intake hole. And also be hard so that it do not get affected
by the sharp edges of the cylindrical boul and not get damage due to the stress
develop due to pulling action as single nut rotate at the time so the whole force
come on single bolt that develop tensile stress inside bolt.
Material used: -EN-8(Hardness 30Rc).

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6. Nut: -
There are eight nut used in whole assembly. Four are used to tight bottom
plate, split plate and upper plate to work as a single body. To transmit the rotary
force into linear force via threads in to the bolt it should be hard so that it do not
get affected by the applied through the spanner. The thread does not get damage
when the force comes on the single nut at the time.

Material used: -EN-8(Hardness 30Rc).

Manufacturing Sequence: -

A) Base Body: -
i) Raw material: - Mild Steel of 87mm diameter X 15mm thickness
ii) Turn the job to the required dimension as shown in drawing of base
body.
iii) Taper the job to the required angle by offset cutting.
iv) Drill the four hole of 11mm diameter X 13mm deep at the PCD of 60mm

diameter
v) Make the counter bored of 15mm diameter X 4mm deep.

vi) Mill the plate to get the slot of 8mm width X 85mm length X 3mm
height.
vii)Heat treats the component around 25-30Rc.

B) Split plate:-
i) Raw material: - 1) EN -8 of 93mm diameter X 5mm thickness
2) Also required the cylinder of EN-8 having 20mm
internal diameter X 32mm outer diameter X 10mm height.
ii) Turn the job to the required dimension as shown in the drawing.
iii) First up all for 91mm diameter plate: -
1) Make the four oblong hole of 11mm diameter X 15 mm
total length as shown in drawing.
2) Drill the hole of 30mm diameter at the center of plate.

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3) Cut the opposite side of the plate as shown in drawing with

dimension of 5.5 mm on both side.
4) Mill the slot of 8mm width X 80mm length X 3mm height.

iv) For the small cylinder: -Turn the job to the required dimension of 22mm
internal diameter X 30mm external diameter X 8mm height shown in drawing.
v) At the end of this join the two job together by means of welding and
finish the surface by blackodising.
vi) Heat treats the job to get the 30Rc hardness.

C) Upper Plate: -
i) Raw material: - EN-8 of 85mm diameter X 10mm thickness.
ii) Shape to the required dimension as shown in drawing.

iii) Drill the hole of 31mm diameter.

iv) Drill the four hole of 11mm diameter at the PCD of 60mm diameter.
v) This plate has hardening of 25Rc.

D) Bolt: -
i) Raw material: - EN-8 of 12mm diameter X 100mm length. Having head
of 14mm diameter X 5mm thickness.
ii) Turn the job to the required dimension as shown in the drawing.
iii) Turn the thread of M10 X 1mm pitch X 80mm length.
iv) Give heat treats to the bolt till 30Rc.

E) Nut: -

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i) Raw material: - EN-8 of hexagonal nut of flat side to flat side distance of
19mm X thread of M10 X 1mm pitch X 12mm height.
ii) The nut is of standard size of 10mm X1mm pitch.
iii) Heat treats the four nut till the hardness of 30Rc.

iv) Other four are not required of much hardness.

F) Boule: -
i) Raw material: - EN-8 of two part as follows: -
1) Pipe of 122mm internal diameter X 142mm outer diameter X
27mm height.
2) Plate of 142mm diameter X 12mm thickness.
ii) First up all pipe of ID-122mm and OD-142mm
1) Turn the pipe to the required dimension as shown in drawing.
Having ID-120mm and OD-140mm.
2) Make the two slot on opposite side as shown in drawing,

having round at the end of 15mm diameter x 86mm total length.

iii) Then the plate of 142mm diameter: -

1) Turn the plate to the required dimension as shown in drawing.
2) Make four hole of 11mm diameter on the PCD of 60mm

diameter.
iv) Then join the pipe and the plate as required and shown in drawing by
welding process.
v) Polish all the sharp edges.
vi) Then heat treats the final product till we get 20Rc hardness.

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Method of operating the puller: -

Required material during operation: -

Puller set, two spanner of 19, one screw driver, diesel, oil, cotton
rages.

Procedure: -

1) First clean the seat with diesel and cotton rages to remove the carbon that
get stuck on the body of the seat and also at gripping area.
2) Disassembled the puller in to the two parts as boule and loosely fitted
three plates.
3) Insert the puller into the hole from which the seat to be removed from the
head of the engine.
4) At the bottom of the valve seat split out the split plate by the finger if is
not get split then apply little force by screw driver.
5) Confirm that the plate is well engage with seat or not, in the case split
plate is not get engage then remove the puller and clean the bottom area of
valve seat.
6) If the split plate get engage then move down upper plate on it and tighten
the nut so that the three plate work as the single plate.
7) Then apply oil around the valve seat and on the thread of the puller and
on the surface of boule where friction takes place.
8) Insert the boule on the four stud that will rest on the surface of the head.
Make sure there is not any obstacle in between head and boule.
9) Move the nut down till the surface of the boule. Hold the nut in to the
spanner of number 19 and rotate the opposite nut simultaneously with same
force.
10) Apply constant torque instead of giving jerks.
11) At the beginning it will take more torque. In case we can see the moment
inside by the slot provided on the boule to check whether the seat is coming
out or not.

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12) Once the seat is pulled out remove the nuts which are on the boule. We
get the valve seat separate out of cylinder head.
13) Repeat the same procedure for removing other seat.

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Increase in Dia
Reduce after splitting.
Diameter.

Direction
of applied
torque.

Inserting Spanner.
The Boule.

Seat disassembled
from head of engine
by puller.

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See
Throug
h Slots

Puller use to remove the valve seat.

Boule.

Split
Plate.

Upper
Plate.

Base
Body.

Different parts of puller.

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