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ABSTRACT
This project report on “Design and manufacture of a three cylinder Engine-Block, using Aluminum Alloy” seeks to give a comprehensive account on how this project work was carried out, a description of the work using part drawing and assembly drawing, Bill of engineers measurement and Evaluation as to reveal the overall cost of the project. The engine block produced is only a model and not intended to be subjected to actual conditions as the usage may require. The choice of Aluminum as the basic materials is due to its lighter weight, corrosion resistance and its casting properties. A wooden pattern of the intended shape and dimension with some allowances was produce and a sand mound prepared. As the Aluminum is melted piece that replicate the pattern. Finishing operations produces the required surface finish and cool and holes on the block. Thus, Aluminum can be cast to give an engine block with all intricacies obtained.
TABLE OF CONTENTS
TITLE PAGE:
DECLARATION ii
CERTIFICATION iii
DEDICATION iv
ACKNOWLEDGEMENT v
ABSTRACT vi
TABLE OF CONTENTS vii
LIST OF TABLES viii
CHAPTER ONE 1
INTRODUCTION 1
1.1 Background 1
1.2 Statement of Problem 4
1.3 Aim and Objectives 5
1.4 Significance of Study 5
1.5 Scope of Study 6
CHAPTER TWO………………………………………………………………..………….7
LITERATURE REVIEW 7
CHAPTER THREE 16
DESIGN AND MANUFACTURING 16
3.1 Design considerations 16
3.2 Design Analysis 17
3.2.1 Pattern Design 17
3.3 Calculations for Pouring Velocity 25
CHAPTER FOUR 31
TESTING/RESULTS AND DISCUSSION 31
4.1 Testing 31
4.2 Safety Precautions 35
4.3 Maintenance Procedures 35
CHAPTER FIVE 37
CONCLUSION AND RECOMMENDATIONS 37
5.1 Conclusion 37
5.2 Recommendations 38
REFERENCES 40
CHAPTER ONE
INTRODUCTION
1.1 Background
Nowadays, the suppliers of engine block are constantly striving to manufacture a better and lighter block in order to improve and enhance the efficiency of automobile. The engine block is the largest an d more intricate single piece of metal used in an internal combustion engine on to which other important part are mounted. It also can be otherwise called a cylinder block. A cylinder block is the central working part of a reciprocating engine which houses the piston to create compression needed to generate power. The cylinder holes (for piston) and other hole for passage of coolants. The engine block (cylinder block accommodates the following components, these are: piston, camshaft, turning chains, rocker arms. It accounts for about 25%-30% of total weight of the engine (Ngugen, 2005).
The first successful internal combustion engine which was used in automobile was built by Siegfrid Marcus in (1864), it was an upright single cylinder, two stroke petrol engine. Today, engines have come to their maximum development and skill developed for years to come. This development has caused increase in power, durability, resistance to wear, and efficiency of the engine. (ASME, 2005).
However during operation, the engine block (cylinder block) is subjected to excessive-heating, stroke loading of a piston and compressive forces of the interconnecting chamber. The block must therefore, consist of the following:
Resistance to wear as a result of reciprocating actions of the piston.
Resistance of compressive stresses imposed by the loads on the block.
Resistance to elongation under action of excessive heat that may alter the geometry of the block.
Resistance to corrosion due to actions of steam and combustion products.
Hence for the engine-block to withstand the above conditions, it must be built with cast iron due to its strength, low cost and wear resistance. But as the engine becomes more complicated, Engineers found new materials to reduce its weight as well as to increase strength and wear resistance. And a common alloy which was used is Aluminum Alloy. This is more popular due to its low weight, its better thermal conductivity compared to grey cast iron, durability, fatigue strength, corrosion resistance, accuracy of measurement due to excellent machinability and finally good recycling possibilities to make manufacturing inexpensive.
In addition to reduction of weight, thermal balance of the engine and also the engine warms up faster and more evenly. (Anyalebechi, 2005).
Furthermore, the functional requirement of an engine block should have the following:
High resistance thermal expansion
High compressive strength
Good thermal conductivity
Good machinability and castability combined with shock loading and thermal stresses.
Also, to manufacture the engine-block using material with the above requirements, casting processes are used. A sand mold is prepared and molten Aluminum is poured into a pattern. The pattern is the main tool required to form the mold which when the molten Aluminum is poured into, it solidifies to give the engine-block. After casting processes are over, the casted engine-block is passed through few machines to get to a surface finish and it required features. The resulting engine-block contains all features on the pattern lighter in weight and good surface finish. This then forms the prototype of the model.
1.2 Statement of Problem
Every engine requires maintenance to increase its efficiency or to restore it to working-order; this requires that certain proactive measures or activities be conducted on the engine. These activities are often difficult when it involves operations on the engine-block.
When an I.C engine knocks due to overheating problem, it is often required that the engine-block be replaced with a new one or regrinded. And acquiring a new engine-block from a manufacturer involves serious financial losses, time loses from placement or order to time of delivery and prolonged downtime of facilities awaiting repairs. An attempt to overcome these problems requires the local technology on casting/fabrication of the engine-block be encouraged.
Design and maintenance of a three cylinder block (prototype) for I.C engine-block based on an already designed pattern. Hence, any shape of engine block can be casted with ease enhancing its local fabrication and preventing over dependence on imported ones.
1.3 Aim and Objectives
To design and manufacture a 3-cylinder Engine Block proto-type using Aluminum material by means of casting method as viable method to produce a cylinder block using local technology; to achieve this goal, thus below are the objectives:
To adapt theoretical knowledge and skill acquired by years of engineering study into practice as to bridge the gap between theory and practical works.
To advance skills in casting technology in the production of complicated shapes.
1.4 Significance of Study
This project seeks to promote acquisition of skills in indigenous casting technology and manufacturing. It afford researchers review advancement, opportunities to improve/boost up an existing casting design and maintenance of engines. This practice is of particular benefit to society as it advances skills which promotes or integrates local technology level of an internal combustion engine (I.C.E.).
1.5 Scope of Study
Design and manufacture of a 3-cylinder Engine Block is intended to use low cost, lightweight, castable material (Aluminum) to cast an engine-block model whose pattern is already in design. This however does not include the practical application of the cast-block in engine as to ascertain its workability. This product is only a prototype model.
Also, other manufacturing processes such as joining, powder metallurgy, machining etc are not included in this work.