The document discusses the manufacturing process of engine components. It describes the steps as: 1. Casting of the engine block using conventional or expendable patterns. Other components like cylinder heads, crankshafts and connecting rods are also cast or forged. 2. The castings undergo machining and heat treatment processes. Pistons are manufactured through gravity casting, squeeze casting, and then machined. 3. Valves are upset forged and heat treated to improve strength and wear resistance. Cylinder liners and piston rings are also manufactured to complete the engine assembly.

1. MODULE I

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

4. Engine Block or Cylinder Block

5. Engine Block or Cylinder Block

6. 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.

7. 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.

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

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
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

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

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

12. 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.

13. The 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.

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

15. 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.

16. 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.

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.

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.

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

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

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

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

24. 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.

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

26. MACHINING PROCESS OF ENGINE BLOCK