4 engine block

LEARNING

1. MODULE I

2. Module I Manufacturing of Engine Components: Casting of engine block ( conventional and expendable pattern). machining of engine blocks in machining center . Preparation of casting for cylinder heads, forging of crank shaft, connecting rod and gudgeon pins. machining and heat treatment. casting of piston by gravity casting, squeeze casting, machining and finishing, upset forging of valves, heat treatment and surface improvement. cylinder liners and piston ring manufacturing.

3. Engine Block or Cylinder Block

4. Engine Block or Cylinder Block

5. Engine Block or Cylinder Block Cylinder block is made from grey cast iron or Aluminium Alloys. The cylinder liner is manufactured from cast iron alloyed with chromium, vanadium and molybdenum. Cast iron contains graphite, which assists lubrication, whereas the alloying elements help resists corrosion as well as improve wear resistance at higher temperature.

6. Engine Block or Cylinder Block Contd… A cylinder block is a unit comprising several cylinders (including their cylinder walls, coolant passages, cylinder sleeves). The metal casting in which the cylinders of an internal-combustion engine are bored. The engine block is a single unit that contain all the pieces for the engine . The engine block is manufactured to withstand large amount of stress and high temperature.

7. Required Material Properties The manufactured product must possess High strength High modulus of elasticity High abrasion resistance High corrosion resistance

8. Cast iron :- Gray cast iron Gray cast iron alloy have been the dominant metal that was used to manufacture conventional gas-powered engine blocks Gray cast iron alloys typically contains 2.5 - 4 wt.% carbon 1 - 3 wt.% silicon, 0.2 - 1.0 wt.% manganese, 0.02 - 0.25 wt.% sulfur, and 0.02 - 1.0 wt.% phosphorus ADVANTAGE It has excellent damping capacity, good wear and temperature resistance, is easily machineable and is inexpensive to produce DISADVANTAGE They are relatively weak and are prone to fracture and deformation

9. Casting Processes of Engine Block or Cylinder Block PATTERN MAKING PROCESS:

10. The three core boxes that produce the inside of the crankcase.

11. On the left is the core box for the cam follower cavity on the right lower is the core box for the standard bore engine, cylinder water jacket.

12. T he holes in the side of the core box (bottom left) match the core prints on the left side of the block . While serving the purpose of locating the cylinder water jacket core, they also become the core/freeze plug in the block.

13. The pattern mounted into the molding box along with the runner and ingate system ready to produce a mold .

14. CASTING PROCESS The two halves of the mould, the blue blocks are filters in the ingate section where the metal will be poured into the mould. These filters help ensure that only clean metal enters the completed mould during casting.

15. The core provides the water jacket space around the cylinders . The core has been painted (darker colour) to seal in the gas generated within the core during the casting process . The gas escapes through the pink core prints (locators) and out of the mould through the vents that can be seen at the left and right ends of the mould.

16. The mould completed with all cores glued into position and ready for casting. The metal is poured into the mould through the smaller front centre hole and fills the mould from the bottom back up to the top through the risers which are the 8 larger holes. As the casting cools the molten metal in the risers is drawn back down into the casting.

17. The first Aluminium Block casting . This casting was rough machined and sectioned as a means of determining that the pattern equipment was correct and that the casting had a correct wall thickness.

18. MACHINING PROCESS The machined head gasket face and note the threaded freeze plug holes

19. The finished block with Cylinder Head and Weber Manifold. The block is now ready for line bearing and camshaft bearing bores

20. From the left two 3.8 litre , one standard 3 litre and two 3.2 litre . Cylinder liners are now installed.

21. The block is set up for line boring the crank and camshaft bearing housings.

22. The boring bar is carefully set in preparation for boring. The boring bar has multiple tools and will bore all the housings in one operation.

23. Another view showing the block with crank and cam trial installation.

24. MACHINING PROCESS OF ENGINE BLOCK