Manufacturing Processes of Engine Blocks
- 1. Guided by: Prof. Harpreet Singh Presented by: Sandeep(2015meb1114)
- 2. 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
- 3. Lasting the life of the vehicle Housing of internal moving parts and fluids Ease of service and maintenance Withstand pressures created by the combustion process
- 4. Manufactured product must posses High Strength High Fatigue Strength High Modulus of Elasticity Corrosion Resistance Low thermal expansion coefficient Optimized thermal conductivity Low Density
- 5. Gray cast iron 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.
- 6. 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.
- 7. 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
- 8. Most common process is sand casting In some cases die casting is also used
- 9. Both wood or metal patterns are being used
- 10. Widely used in engine block casting is green sand mold casting. A combination of silica sand, clay, and water Pattern with wood or metal frame. Compacted by applying pressure or vibrating on the metal frame.
- 12. The core shown below provides the space for water jackets around the cylinders
- 13. Then the water jackets and cylinder molds are arranged in the main mold as a one cube. The mold is then tightened using clamps to withstand the pressure of gravity when pouring molten metal
- 15. The rough aluminum cylinder block is done with surface grinding to get smooth surfaces in the head gasket face and the faces where other components are fitted
- 16. Bearing caps are fitted temporally for the line boring of the main bearing bores. line boring of the crank and the cam shaft bearing housings. boring bar contains multiple tools so in one operation all the boring operations are done.
- 17. Strength of the sand has to be high to maintain a rigid shape. thermal stability The sand mixture must be well compressed around the pattern to get a higher strength The risers has to be well planed The cooling rate has to be up to the standard
- 18. If the permeability of the sand used for casting is high, the strength and the surface finish of the mold will be reduced. If the thermal stability of the sand is low, the mold may crack due to the molten metal. If the compression of the sand is low the casting would not be able to shrink and will end up with cracking. If the risers get solidified before the other parts of the casting, it would give a engine block with less strength. If the molten alloy is not up to standard it will failure in high running conditions.
- 19. http://newengineeringpractice.blogspot.in/2011/08/en gine-block-manufacturing-process.html https://blog.miragemachines.com/line-boring- machine-applications-capabilities-and-features https://www.youtube.com/watch?v=yXVLbzI3xTE
- 20. QUESTIONS!!
- 21. Thanks…