Engine block manufacturing process

Engine block
MEL-202
MANUFACTURING WITH METALLIC MATERIALS
ROHIT ANAND
2013MEB1108
Under the guidance of -
Dr Harpreet singh
(asso.professor SMMEE)
HEART OF THE ENGINE ??

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 performance
Vehicle
 The engine block is manufactured to withstand large amount of stress and high
temperature
Adapted from :http://www.eng.buffalo.edu/~llee3/Projects/LengFengLee_MAE364ProjectReport.pdf

Adapted from :http://www.eng.buffalo.edu/~llee3/Projects/LengFengLee_MAE364ProjectReport.pdf

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.
Adapted from :http://www.ewp.rpi.edu/hartford/~ernesto/F2010/EP2/Materials4Students/Lenny/Nguyen2005.pdf

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

Required Material Properties (contd)
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.

 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

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

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

Casting Processes
PATTERN MAKING PROCESS:
Adapted from :http://203.26.107.37/dmd/development-manufacturing-process/dmd-pattern-making/

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

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.

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 welsch/core/freeze plug in
the block.

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

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.

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.

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.

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.

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

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

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

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

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

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

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.

The engine fires for the first
time

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

Engine block manufacturing process

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