seminar presentation for topic engine block with engine parts and casting of blocks and schematic diagram with brief description about different parts and also with moualding process of the different parts
1. National Institute Of Technology
Warangal
DEPARTMENT OF METALLURGICAL AND MATERIALS
ENGINEERING
1
G
Under the guidance of -
Dr. N. Narasaiah
(Assi.Professor NITW)
PAVAN KUMAR RAI
MME 175505
3. Engine block
The engine block is a single unit that contain all the pieces for the engine .
The block serves as a structural framework of the engine and carries the mounting pad by
which the engine is supported by the chassis
The block is made of cast iron and sometimes aluminum for higher performanceVehicle
The engine block is manufactured to withstand large amount of stress and high temperature
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6. Functional Requirements of a Cylinder Block
Engine blocks are a critical component of an engine, it must satisfy a number of functional requirements
These requirements include :-
1. Lasting the life of the vehicle
2. Housing internal moving parts and fluids
3. Ease of service and maintenance
4.Withstand pressures created by the combustion process.
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7. Required Material Properties
The manufactured product must possess
High strength
High modulus of elasticity
High abrasion resistance
High corrosion resistance
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8. Required Material Properties
High strength is a particular concern in diesel engines, since compression ratios are normally 17.0:1
or higher (compared to about 10.0:1 for conventional engines)
The material should also have
Low density
Low thermal expansion (to resist expanding under high operating temperatures)
Low thermal conductivity (to prevent failure under high temperatures)
Based on the listed requirement industries have used cast iron and
aluminum alloys to manufacture the blocks.
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9. 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 6 and 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
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10. Compacted Graphite Cast Iron
Compacted graphite cast iron (CGI), which was accidentally discovered while trying to produce
ductile cast iron, possesses higher tensile strength and elastic modulus than gray cast iron
Like gray cast iron, compacted graphite cast iron has good damping capacity and thermal
conductivity, but its difficulty to machine has limited the wide-scale use of CGI
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11. Aluminum Alloys
It was discovered to reduce the overall weight of the vehicle
There are two practical implications :
Improved performance-to-weight ratio
Increased fuel efficiency
The drawbacks of using aluminum in engine blocks are that they are more expensive to manufacture than
cast iron alloys
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13. The three core boxes that
produce the inside of the
crankcase.
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14. 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.
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15. The pattern mounted into the
molding box along with the runner
and ingate system ready to produce a
mold.
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16. 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.
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17. 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.
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18. 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.
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23. ASSEMBLY AND TESTING
The 3.8 litre engine assembled and
ready for a test run.To accommodate
the large bore on this engine, the
water pump has been moved forward
on the block casing, so a special
pulley has been machined with the
correct offset for the belt.
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25. The initial test run of the 3.8 litre Engine produced the following:
• Horsepower 295 at 6000RPM
•Torque 300ft/lbs at 3500RPM
Test conditions:
•98′ research octane fuel (equiv. 94 research/motor octane)
•10.5 to 1 compression ratio
•33 degrees total advance
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26. REFERENCES
Adapted from
:http://www.eng.buffalo.edu/~llee3/Projects/LengFengLee_M
AE364Proj
Adapted from
:http://www.ewp.rpi.edu/hartford/~ernesto/F2010/EP2/Materi
als4Students/Lenny/Nguyen2005.pdf
Adapted from :http://203.26.107.37/dmd/development-
manufacturing-process/dmd-pattern-making/
Adapted from :http://dmd/development-manufacturing-
process/dmd-pattern-making/ 26