Engine Block Report

Manufacturing Report: Engine Block Casting Name: Louis Fernandez

48621: Manufacturing Engineering Project Report: Engine Bloc

Louis Fernandez 12!!!8!"

#a$le of content

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LIST OF FIGURES................................................................................ .

I!TRO"UCTIO!# $!$L%SIS $!" "I$GR$M......................................& 1.1. DESCRIPTION OF ENGINE BLOCK AND ANALSIS OF CO!PONENTS............................" 1.". DIAGRA!.................................................................................................... #

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M$TERI$L SELECTIO! $!" 'USTIFIC$TIO!...................................... (

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M$!UF$CTURI!G..........................................................................* #.1. DETAILED DESCRIPTION OF !AN$FACT$RING PROCESS %INCL$DES FLO&C'ART(.........) #.". RE*$IRED !AN$FACT$RING E*$IP!ENT............................................................+ #.#. ALTERNATI,E !AN$FACT$RING PROCESSES.........................................................+

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+U$LIT% $SSUR$!CE $!" I!S,ECTIO!.......................................... -

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ESTIM$TIO! OF M$!UF$CTURI!G COST.........................................).1. TI!E.......................................................................................................... ).". LABO$R......................................................................................................  ).#. E*$IP!ENT................................................................................................. 

LIST OF FIGURE

#a$le 1: %ifferent co&ponents of t'e engine $loc and t'eir functions((((((((((((((((((((((((((((((((((((2 #a$le 2: Possi$le &aterials t'at can $e used in t'e &anufacture of t'e engine $loc(((((((((((((((4 Figure 1: ) flo*c'art of 'o* an engine $loc can $e sand casted((((((((((((((((((((((((((((((((((((((((((((! #a$le +: ,'o*s possi$le defects t'at can occur during t'e casting process(((((((((((((((((((((((((((((((-

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1. In/rodu0/ion Ana23sis and Dia4ram #'is report is concerned *it' identif.ing t'e &anufacturing processes re/uired to create an engine $loc( #'is section *ill introduce t'e general functions of an engine $loc t'roug' t'e anal.sis of its co&ponents and description of *'at it is used for(

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Des0ri5/ion o6 en4ine 72o08 and ana23sis o6 0om5onen/s

)n engine $loc0 &ore co&&onl. no*n as c.linder $loc0 is t'e largest part of t'e engine t'at 'ouses t'e c.linders0 &aing up approi&atel. a /uarter of t'e engines o3erall *eig't( ts pri&ar. purpose is to generate po*er to ena$le &otion 5con3erting one t.pe of energ. into &ec'anical energ.( #'is is done $. 'ousing different parts suc' as t'e piston0 crans'aft and ca&s'aft( t also gi3es *a. to a 3ariet. of fluids 5suc' as t'e fuel0 coolant0 oil or air to ena$le t'e process *it'in t'e engine $loc to $eco&e &ore efficient and effecti3e( )s &entioned0 t'e &ain purpose of t'e engine $loc is to 'ouse t'e c.linder and con3ert one t.pe of energ. into &ec'anical energ.( n &ost product0 suc' as an auto&oti3e0 t'is is done t'roug' t'e c'anges of te&perature and pressure *it'in t'e c.linder to cause co&$ustion( #'e &ain parts *it'in t'e engine $loc and t'eir function is included in ta$le one( Eac' co&ponent &ust $e &ade of 'ig' /ualit. &aterials due to t'e etre&el. 'ars' *oring condition( For ea&ple0 in an auto&o$ile0 t'e engine is used al&ost e3er. da. *'ere t'ousands of co&$ustion occurs and t'e pistons &o3e at 'ig' speeds to cause c'anges in pressure and te&perature( Component 7rancase

7.linder 'ead

ntae9e'aust 3al3es

Function ouses t'e crans'aft t'at turns • t'e cran to po*er t'e engine Location of t'e co&$ustion • c'a&$er *'ere co&$ustion occurs )lso 'olds t'e piston t'at &o3es • up and do*n due to c'anges in pressure Ena$les air to enter and lea3e t'e • engine $loc

Ta72e 1: Di9eren/ 0om5onen/s o6 /e en4ine 72o08 and /eir 6un0/ions

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48621: Manufacturing Engineering Project Report: Engine Bloc 1.".

Louis Fernandez 12!!!8!" Dia4ram

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". !a/eria2 se2e0/ion and ;us/i<0a/ion #'e &ain purpose of t'e engine $loc is to 'ouse different co&ponents t'at *ill ena$le for t'e production &ec'anical energ. t'roug' co&$ustion( #'is &eans te&perature and pressure to *ill reac' etre&el. 'ig' le3els( #'erefore0 t'e &aterial t'at t'e engine $loc is &ade out of &ust $e dura$le enoug' to *it'stand t'e 'ig' le3els of 'eat and pressure generated *'en co&$ustion taes place( t &ust also $e strong enoug' to a$sor$ t'e 3i$rational energ. *'en t'e internal parts0 suc' as t'e crans'aft0 connecting rod and piston0 is in &otion( Failure to do so *ill result in fracture of t'e product due to t'e 'ig' rate of &o3e&ent of t'e internal parts( n order to full. satisf. t'ese re/uire&ents0 t'e &aterial &ust 'a3e t'e follo*ing p'.sical and &ec'anical properties: ig' and &odulus of elasticit. to acco&&odate *it' t'e 'ig' le3els of pressure • generated *it'in t'e c.linder Lo* t'er&al epansion as a 'ig' t'er&al epansion can result in fracture of t'e • engine as a *'ole if t'e &aterial cannot resist epanding at 'ig' te&peratures ig' t'er&al conducti3it. to pre3ent o3er'eating t'e engine $. gi3ing out 'eat as fast • as possi$le ig' specific strengt' to &ai&ize t'e a&ount of strengt' t'e product can 'a3e *'ile • $eing lo* *eig't 7orrosion resistant as parts of t'e engine $loc *ill 'a3e fluids passing t'roug' it • Furt'er&ore0 *'en looing at it fro& a &anufacturing 3ie*point0 t'e &aterial &ust $e easil. casted and 'a3e good &ac'ina$ilit. to reduce cost as *ell as &anufacturing ti&e( #a$le t*o s'o*s possi$le &aterials t'at can $e used t'at contains t'e properties discussed( Material Grey cast iron alloys

Aluminum alloys

Description 7ontains &ajorit. 2(! 4; car$on and 1+; silicon

+1= 'as +(!; copper and 6; silicon )+!6 'as -; silicon and "(+; &agnesiu& 5&a "(2; iron

Compacted graphite iron (CGI)

Advantage Lo* cost 5as it can $e easil. &ac'ined and 'ig'l. a3aila$le
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,i&ilar properties as gre. cast iron allo.s $ut &ore lig't*eig't Lo* pouring te&perature can $e ac'ie3ed co&pared to cast iron 5due to lo* &elting point of pure alu&inu& +1= alu&inu& allo. 'as good casting features0 corrosion resistance and good t'er&al conducti3it. )+!6 allo. 'as si&ilar properties as +1= $ut can o$tain 'ig'er strengt' *'en it undergoes 'eat treat&ent

ig'er tensile strengt' and &odulus of elasticit. attained *it' lo*er *eig't *'en co&pared *it' gre. cast iron
Disadvantage ea3ier *'en co&pared to alu&inu& ig'er pouring te&perature relati3e to alu&inu& ig'er costs *'en co&pared *it' gre. cast iron )+!6 allo. is &ore $rittle due to t'e lo*er &odulus of elasticit. •

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Li&ited &ac'ina$ilit. &aing it 'ard to process relati3e to gre. cast iron

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Ta72e ": Possi72e ma/eria2s /a/ 0an 7e used in /e manu6a0/ure o6 /e en4ine 72o08

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#. !anu6a0/urin4 #'e &anufacturing of an engine $loc is done using t'e casting process( #'e casting tec'ni/ue used is usuall. sand casting $ut die casting can also $e used( o*e3er0 due to t'e 'ig' te&perature of t'e &olten &etal0 it is 'ig'l. liel. t'at t'e die *ill *ear out /uicl. resulting in 'ig'er costs in replacing t'e da&aged e/uip&ent( #'erefore0 t'e proposed casting &et'od to $e used in t'e &anufacture of t'e engine $loc is sand casting( )fter t'e engine $loc 'as $een casted0 it is necessar. to perfor& certain &ac'ining operations to satisf. t'e re/uire&ents of t'e engine $loc( #'ese operations &a. include undergoing 'eat treat&ent0 cleaning0 cutting an. unnecessar. parts0 drilling and $roac'ing(

#.1. De/ai2ed des0ri5/ion o6 manu6a0/urin4 5ro0ess %in02udes =o>0ar/( ,and casting is a t.pe of ependa$le &old casting *'ere a &olten &etal is poured into t'e &old *'ere it can solidif.( >nce t'e &etal 'as $een solidified0 t'e sand &old is $roen 5usuall. $. 3i$rating t'e &old9cast so t'at t'e casted &etal can $e taen( #'e t.pe of &old casting t'at is used for t'e &anufacturing of t'e engine $loc is no*n as green sand &old casting0 ?green i&pl.ing t'at t'e &oisture is left on t'e sand rat'er t'an putting it in an o3er to dr. it 5no*n as dr. sand &old( ) generalized flo*c'art of 'o* t'is occurs is s'o*n $elo* Pattern and core &aing

Preparation of sand

Mold &aing

Melting of &etal

Pouring

nspection and cleaning

Finis'ed casting

,olidification and cooling

Re&o3al of sand &old

Mac'ined to get correct di&ension and s&oot' surface finis'

Fi4ure 1: A =o>0ar/ o6 o> an en4ine 72o08 0an 7e sand 0as/ed -



#'e &anufacturing of t'e engine $loc starts *it' t'e pattern and core &aing( #'e pattern can $e &ade out of a 3ariet. of &aterials suc' as sand0 &etal or plastic( #'e o3erall t.pe of pattern &aterial used *ill depend on 'o* &uc' t'e &aterial *ill $e used to create a pattern 5eg &etal patterns0 alt'oug' epensi3e to &ae0 lasts longer t'an *ood and plastic( Furt'er&ore0 t'e core is also created to define t'e internal surface of t'e &etal( #'e core is often &ade out of t'e sa&e &aterial t'e &old is &ade out of( >nce t'e pattern 'as $een created0 &old &aing is t'e net step( #'e &old is generall. &ade out of sand *it' cla. and *ater used as a $inding agents to 'old t'e *'ole &old toget'er( @'en t'e sand &iture is read.0 it is poured onto t'e pattern and 3i$rations are applied to it 5or ?'and ra&&ed $. a foundr. *orer to co&pact and free t'e air $u$$les in t'e &iture( %uring t'ese stages0 t'e cope and drag 'a3e t'eir o*n independent patterns so t'at t'e. can $e fa$ricated independentl.( @'en $ot' t'e cope and t'e drag 'a3e $een &ade0 t'e core is positioned and t'e t*o 'al3es are cla&ped toget'er0 read. for casting( 7asting t'e engine $loc si&pl. consists of t'e pouring of t'e &etal0 solidif.ing and cooling( ) fe* factors &ust to $e considered during t'e pouring process to ensure t'e engine $loc is successfull. casted( #'is includes0 $ut are not li&ited to: #e&perature of &olten &etal: t'e 'ig'er t'e te&perature past t'e &elting point t'e • $etter as it is &ore fluid and it is &ore liel. to sta. li/uid during t'e pouring process Rate of pouring: t'e &olten &etal &ust $e poured at a rate fast enoug' so t'at it does • not solidif. during t'e pouring stage $ut not so fast t'at it *ill pre3ent a la&inar flo*

>nce t'e &etal 'as $een poured0 it solidifies and cools inside t'e &old( )fter t'is0 t'e casted &etal is re&o3ed fro& t'e &old $. appl.ing 3i$rations onto it( t is t'en cleaned and &ac'ined to get accurate di&ensions and s&oot' surface finis'( ) series of &anufacturing operations are used on t'e engine $loc to ensure t'at it &eets t'e /ualit. standards9policies of t'e &anufacturer( #'ese operations &a. include undergoing 'eat trea t&ent0 $oring0 drilling and cutting of an. etra and unnecessar. parts(

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Re?uired manu6a0/urin4 e?ui5men/

,and casting is a si&ple &anufacturing process( For t'e &anufacture of t'e engine $loc0 t'e &ain e/uip&ent re/uired are: ,and and $inding agents 5eg *ater0 glue or cla. re/uired to create t'e &old • Material for pattern &aing 5eg *ood0 &etal or plastic • Metal 57<0 alu&inu& allo.s or gre. cast iron allo. t'at is to $e casted to create t'e • engine $loc Furnace 5or so&et'ing si&ilar t'at 'as t'e a$ilit. to &elt t'e &etal • Mac'ineries 5eg lat'e9finla. t'at 'as t'e a$ilit. to operate on t'e casted &etal to get • re/uired di&ensions and surface finis'

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A2/erna/i@e manu6a0/urin4 5ro0esses

#'e &ost appropriate &anufacturing process to create an engine $loc is t'e casting process( o*e3er0 t'ere are different t.pes of casting tec'ni/ues t'at can $e used( )s &entioned $efore0 sand casting is t'e &ost appropriate &et'od as it is econo&icall. 3ia$le *'ilst also 8



$eing a$le to produce co&ple s'apes and geo&etries re/uired for t'e &anufacture of t'e engine $loc( )n alternati3e casting &et'od0 as &entioned $efore0 includes die casting( %ie casting in3ol3es t'e injection of t'e &olten &etal into t'e &old ca3it.( )lt'oug' t'is *ill produce an engine $loc *it' $etter &ec'anical properties and $etter surface finis'0 it can $e costlier as t'e te&perature of t'e &olten &etal can decrease t'e lifespan of t'e &etal &old( #'is *ill result in greater costs in creating ne* &olds(

. *ua2i/3 Assuran0e and Ins5e0/ion Defect Misruns Cold shots

Description Molten &etal solidifies $efore filling t'e &old ca3it. For&ation of s&all solid &etals t'at is &ied *it' t'e &olten &etal due to splattering ) surface defect *'ere t'e surface of t'e casted &etal *ill 'a3e a &iture of sand grains and &etal >ccurs *'en t'e &old cracs 5possi$l. due to lo* t'er&al sta$ilit. of t'e sand or poor sand co&pression

Penetration Mold crack

Ta72e #: So>s 5ossi72e de6e0/s /a/ 0an o00ur durin4 /e 0as/in4 5ro0ess #a$le + s'o*s so&e defects t'at &a. occur during t'e casting process of t'e engine $loc( 7ertain inspection &et'ods and standards for t'e sand &old &ust $e &et to ensure t'at t'ese defects *ill $e pre3ented( #'ese includes: Aisual inspections to detect &isruns and penetration 5or ot'er surface defects of $ot' • t'e &old and casted &etal %i&ensional &easure&ents to ensure t'at tolerances re/uire&ent 'a3e $een satisfied • Radiograp'ic or supersonic &et'ods of testing for eternal9internal defects of t'e • engine $loc Pressure testing to locate leas in &old • ,trengt' of &old &ust $e 'ig' enoug' to &aintain its rigid s'ape during t'e casting • process #'e sand &old s'ould $e co&pacted properl. and 'a3e 'ig' t'er&al sta$ilit. so it • does not crac under 'ig' te&peratures

). Es/ima/ion o6 !anu6a0/urin4 Cos/ ).1.

Time

#'e total ti&e of t'e &anufacture of t'e engine $loc *ill depend on t'ree &ain factors: 1( o* long it taes to create pattern9&old 2( o* long it taes for t'e &etal to &elt0 $e poured on t'e &old and solidif. +( o* long it taes to &ac'ine t'e casted &etal %epending on t'ese factors and 'o* easil. it is to &ac'ine t'e &etal in use0 t'e ti&e *ill 3ar. for eac' &anufacture of t'e engine $loc( For t'e &ini&u& a&ount of ti&e0 it is $est to use alu&inu& allo.s due to its lo* &elting point and ease of &ac'ining( o*e3er0 alu&inu& allo.s cost &ore relati3e to gre. cast iron( =


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La7our

#'e 'u&an la$our re/uired to carr. out t'e &anufacturing operations is li&ited due to t'e ad3ance&ents in tec'nolog.( Man. operations can no* $e carried out t'roug' t'e use of different &ac'ines( For ea&ple0 in t'e &ass production of engine $locs0 &ac'iner. suc' as lat'e 5used to 'elp in operations suc' as drilling and $oring and ro$ots 5used to s'ae out sands are used to carr. out certain operations &ore effecti3el. and efficientl.( o*e3er0 so&e operations can $e carried out $. 'ands0 lie t'e co&pacting of sand can $e carried out $. a foundr. *orer(

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E?ui5men/

For t'e &anufactures of &ost engine $locs0 sand casting is used( #'e &ain e/uip&ent for sand casting include sand and $inding agents suc' as glue0 *ater and cla.( For &ini&u& cost of e/uip&ent0 t'e &aterial t'at s'ould $e used to create t'e pattern is *ood to ensure t'at it is easil. &ac'ined to for& t'e pattern re/uired(

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Engine Block Report

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