University of Engineering and Technology Lahore

Machine Tool & Machining Lab Assignment

Submitted by
Abdullah Mansha 2015-ME-81
Section: B
Submitted to:
Sir Waqas
Sequence of Operation for manufacturing of
Engine Cylinder Block
Casting
Engine block is a one-piece component cast from sand mold. Mold is made
from glue, hardener and sand. This combination of materials can withstand the
intense heat of the molten metal but only for one casting. Mold is made of different
sections called cores that fit together. To make each core sand and glue mixture is
blown in a master mold made of iron. It injects a gas that activates the hardener
which solidifies the mixture. Many cores are attached with the main core. Some
glue is applied between cores so that they do not separate when mold is moved or
flipped upside down.
Aluminum ingots are melted and then poured in the mold. After some time,
aluminum solidifies. After casting, sand is separated from the block. Block is tilted
many times to remove any sand present.

Removal of Runners, risers and sprues

Casted part contains the runners, risers and sprues. These are necessary evil
for the casting. Molten metal passes through runners and sprues and reach
different sections of block. Risers provide molten metal and compensate for the 7%
shrinkage of metal after solidification. After casting these are not needed. These
are machined off from the block.

Milling Operation
Sand casting does not give good finishing. The surfaces produced are also not
flat. Milling operation is done to remove material and flatten the surface. It also
improves the surface finishing. Block is clamped in a fixture and both the top and
bottom decks are milled. Slots and caps are also milled.

Drilling
Most of the holes needed in the block are casted especially the large holes.
The smaller holes that cannot be casted are drilled using drilling machine. Due to
heavy weight of the block clamping is not very much needed. Still it can be clamped
for alignment purposes and to overcome vibration.

Boring
The large holes produced from casting are not of the required diameter
because precise diameter cannot be achieved through casting. Required diameter
casting is achieved by boring operation. Boring tool is first adjusted with the center
of the hole. Then it increases the diameter of the hole. Boring operation is
performed one by one on all the holes.

Tapping
Internal threads are needed for assembling of the block with the other parts
of the engine. Internal threads are produced by tapping operation in which tapping
tool is used. Screws and nuts will be used to assemble different parts together.

Grinding and surface finishing

After all the other operations grinding and surface finishing operations are
performed in the last. These operations are done to improve the finishing of the
block. When other parts will be assembled with the block there should be no gap
between them to increase performance.

Assembling
Caps and other parts are assembled to the engine block. Most of them using
nut and bolts. There machining is done separately and after that they are attached
to the block.
 Fixture for Engine Block
Fixture is independent of the operation. It depends on the shape of the work
piece (faces of Engine block). Fixture of the Engine block should be such that
maximum operations can be performed on one fixture. The fixture shown in the
figure is very simple one and can be used for all faces. It has two plates and the
block is clamped between them. Clamping can be of following types.
1. Mechanical Clamping
2. Pneumatic Clamping
3. Hydraulic Clamping
In this fixture bolts are used to hold the engine block on machine table and
allows operation on head face. For pan face operations block in inverted. For
performing the operation on the end faces de-clamp the block and change the
position of block in such a way that end face come in front of tool for performing
operations. In this way single fixture can be used for more than one operations.
Some operations do not require such a heavy duty fixture because weight of
the block is enough to put a downward force, these operation includes drilling,
boring, reaming and threading. For this purpose, just light clamping is enough