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Design, Development and Analysis of Hydraulic Fixture for machining Engine cylinder block on VMC

Design, Development and Analysis of Hydraulic Fixture for machining Engine cylinder block on VMC

In this paper, the design requirements of the fixture were studied and according to that two types of CAFD had done in CATIA V5. Verification of the fixture design is carried out using ANSYS workbench. Mean while clamping forces are calculated at 40, 50 and 60 bar hydraulic pressure by using analytical and numerical methods which are validated and are taken into consideration during the static analysis of the fixture and cylinder block, so from FEA result the 1 st type of

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Use of FMEA Methodology For Development Of Semiautomatic Averaging Fixture For Engine Cylinder Block

Use of FMEA Methodology For Development Of Semiautomatic Averaging Fixture For Engine Cylinder Block

RPN play an important part in the choice of an action against failure modes. They are threshold values in the evaluation of actions for these failure modes. Total ten items/functions of semiautomatic averaging fixture for engine cylinder block are analysed. Out of these ten, two failure modes clamping system & resting of component in fixture are found higher RPN.For clamping system risk priority number (RPN) becomes 140(where S = 7,O = 4,D = 5) , Thus corrective actions like clamping cylinder selection strictly against cutting forces , pneumatic circuit design with read switch for clamping cylinders, pressure switch & check valves are taken in design stage which resulted in reducing RPN from 140 to 28 (Where S = 7, O = 2 & D = 2).Also, RPN for resting of component in fixture found to be 84(where S = 7,O = 4,D = 3).Thus actions like proper resting of component against clamping ,suitable material for pads etc. are taken in design stage which resulted in reducing RPN from 84 to 14 (Where S = 7, O = 2 & D = 1).
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Static Analysis of V-12 Engine Cylinder Block Using FEM

Static Analysis of V-12 Engine Cylinder Block Using FEM

The Cylinder Block forms the basic framework of the engine. It houses the engine cylinders, which serve as bearings and guides for the pistons reciprocating in them. The analysis of the engine block is to be carried-out to predict its behavior under static loading. The cylinder block has to with stand the stresses and deformations due to loads acting on it. An attempt is made in this paper to perform static analysis on V-12 Engine cylinder block to obtain the variation of the stresses and the deformations at different pressures of 8 MPa, 10 MPa, 12 MPa and 15 MPa on the Engine Cylinder Block. Three dimensional model of the Engine Cylinder Block was created using CATIA V5 R22 software and the mesh is generated using TET Elements. The Analysis of the Engine Cylinder Block is carried-out using Compacted Graphite cast Iron (CGI GJV 450) and NASA 398 (hypereutectic Al-Si alloy) materials using ABAQUS 6.14 software. The mechanical boundary conditions were applied to the Engine Cylinder Block and different pressures are applied and static analysis are analyzed. The results are observed for selecting the best suitable material for the Engine Cylinder Block From the analysis results, it gives a clear idea that the stress distributions in both the cases are nearly same. So in deformation point of view, CGI GJV 450 has less deformation and hence CGI GJV 450 is considered as the best material for Engine Cylinder
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A FEM Investigation for I C Engine Cylinder Block by Varying Thicknesses of Water Jacket

A FEM Investigation for I C Engine Cylinder Block by Varying Thicknesses of Water Jacket

Materials and process selection are key issues in optimal design of industrial products. Recently many materials which have long been used in industry are being replaced by newer materials in order to meet demands of cost reduction and better performance. In the manufacture of mechanical parts, knowledge of material properties, cost, design concepts and their interactions is required. The large number of available materials, together with the complex relationships between the various selection parameters, often makes the selection processes a difficult task. When selecting materials, a large number of factors must be taken into account. The cylinder block is cast from gray iron or iron alloyed with other metals such as nickel, chromium, or molybdenum. Some lightweight engine blocks are made from aluminium. Cylinders are machined by grinding or boring to give them the desired true inner surface. The liners are inserted into a hole in the block with either a PRESS FIT or a SLIP FIT. Liners are further designated as either a WET-TYPE or DRY-TYPE. The wet-type liner comes in direct contact with the coolant and is sealed at the top by a metallic sealing ring and at the bottom by a rubber sealing ring. The dry-type liner does not contact the coolant. Engine blocks for L-head engines contain the passageways for the valves and valve ports. The lower part of the block (crankcase) supports the crankshaft (the main bearings and bearing caps) and provides a place to which the oil pan can be fastened. The camshaft is supported in the cylinder block by bushings that fit into machined holes in the block. On L-head in-line engines, the intake and exhaust manifolds are attached to the side of the cylinder block. On L-headV-8 engines, the intake manifold is located between the two banks of cylinders; these engines have two exhaust manifolds, one on the outside of each bank.
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Development and Testing of the Nonferrous Engine Cylinder Block for Single Cylinder, Four Stroke, Air Cooled Spark Ignition Engine for Two Wheelers

Development and Testing of the Nonferrous Engine Cylinder Block for Single Cylinder, Four Stroke, Air Cooled Spark Ignition Engine for Two Wheelers

The different thermal expansion coefficients of Gray Cast Iron and the Aluminium alloy cylinder block material can cause deformation of the liner and also local heat transfer problems if the liner disengages from the engine block. Particularly the deformation of the liner leads to an increased oil and fuel consumption and increasing emissions. The liner-equipped engine is still unnecessarily large, still has differential expansion and reduced heat dissipation issues, still needs a heavier and larger cooling system, etc.
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KaizeninWorld Class Automotive Company With Reduction of Six Big Lossesin Cylinder Block  Machining Line in Indonesia

KaizeninWorld Class Automotive Company With Reduction of Six Big Lossesin Cylinder Block Machining Line in Indonesia

 Based on the data of Overall Equipment Effectiveness (OEE) on the Cylinder Block machining Line for the period September 2018 - November 2018 the Overall Equipment Effectiveness (OEE) value is found at87% that over then the World Class Manufacturing OEE’s standard 85%, but if compare to Company’s OEE target 95% still have gap 8% for improvement/kaizen.

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Design &Development of Semiautomatic Averaging Fixture for Engine Cylinder Block for Enhancement of Productivity & Quality

Design &Development of Semiautomatic Averaging Fixture for Engine Cylinder Block for Enhancement of Productivity & Quality

II. IMPORATANCE & N EED O F SEMIAUTOMATIC AVERAGING FIXTURE FOR ENGINE CYLINDER BLOCK . After the casting is made, it is send to machine shop for machining as required by customer. It is necessary to ensure that minimum machining allowance is available on all the machined faces before machining the first references in all 3 axes. Subsequent machining is done with respect to the first machined references. This activity of ensuring availability machining allowances is done by marking the casting on a layout marking machine for small quantity of casting .Since this is time consuming activity for mass produced castings, averaging fixtures are used in such cases. Hence averaging fixtures should logically have features to ensure minimum machining allowance and facility to conduct first machining references in 3 axes. [3] Normally 3 small machined pads in one axis and 2 dowel holes on these pads are sufficient to locate the casting, constraining all the three degrees of freedom for subsequent machining either on transfer line or gang of SPM’s. This operation of averaging is mainly done on radial drilling machine.
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Evaluation of the Thermal Performance of Aluminium Alloy Cylinder Block for A Single Cylinder, Four Stroke, Air-Cooled Spark Ignition Engine for Motor Cycle Application by using CFD Technique

Evaluation of the Thermal Performance of Aluminium Alloy Cylinder Block for A Single Cylinder, Four Stroke, Air-Cooled Spark Ignition Engine for Motor Cycle Application by using CFD Technique

344 Initially, the natural convection condition was considered for the Cast Iron engine cylinder block. So, the velocity is assumed equal to 0 m/s. The temperature of the block is considered as 530 K on the inner surface. There is equal distribution of heat from inner surface of cylinder to the outer surface of fins and block as far as the results of CFD are concerned. Temperature on the outer surface is almost the same as compared to the inner surface in natural convection. But as air velocity increases, the temperature of the fins goes on decreasing as it can be seen from above figures.
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Non Linear Heat Transfer Analysis of IC Engine Cylinder Block Using Finite Element Method

Non Linear Heat Transfer Analysis of IC Engine Cylinder Block Using Finite Element Method

transfer of the three internal combustion engine. The thermal analysis results give the idea about the heat transfer rate through the solid material when different materials are used . all the materials used for the analysis shows a promising alternative for the selected engines in thermal point of view . Thermal analysis results proved that A356 is better replacement for conventional materials used in ic engine cylinder block .after conducting the first analysis engine1 shows low heat flux value comparing with other two engines. Transient analysis output shows a more realistic values for heat flux and temperature distribution from the analysis following points are obtained
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Failure Analysis of Cracking Defect in Engine Cylinder Block

Failure Analysis of Cracking Defect in Engine Cylinder Block

Simulation of MAGMA software to engine cylinder block indicated that there is relatively high tensile stress (ranging from 69.2Mpa to 95.3Mpa) in the cracking zone. Though statistics to the amounts of failed engine cylinder block shows there is low rate of cracking failure events, cracking may occur under the circumstance of the presence of inclusions like nitrogen compounds and unqualified microstructure like E type flake graphite. The presence of inclusions like nitrogen compounds leads to the concentration of stress in castings and wrecked the continuity of the base, causing the occurrence of cracking on the condition of tensile stress. So, it could be known that the failure of engine cylinder block is the comprehensive consequences of abnormal microstructure, the presence of inclusions and tensile stress in casting process.
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Enhancement of heat transfer on Engine Cylinder Block

Enhancement of heat transfer on Engine Cylinder Block

.The theoretical rate of heat transfer is calculated for old and new design ,its value is 8700.8 watts and 8724.6 watts. The complete structure of the engine cylinder block is modeled by using the SOLID WORKS software. The analysis was carried using ANSYS Work bench software. The maximum and minimum temp was 673K and 422.2 K on the old design whereas the temp variation is found to be of maximum as 673 K and minimum as 438.7 K on modified engine block.

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DESIGN AND THERMAL ANALYSIS OF CYLINDER BLOCK

DESIGN AND THERMAL ANALYSIS OF CYLINDER BLOCK

In the essential terms of machine components, the distinctive crucial parts of a motor, (for instance, cylinder(s), chamber head(s), coolant areas, admission and fumes entries, and crankcase) are hypothetically specific, and these thoughts can all be instantiated as discrete pieces that are catapulted together. Such development was to a great degree far reaching in the early numerous years of the commercialization of internal combustion engines (1880s to 1920s), and it is still sometimes used as a piece of particular applications where it remains gainful (especially vast motors, also some little motors). Be that as it may, it is no more the normal strategy for building most petrol motors and diesel motors, in light of the way that for any given motor setup, there are more viable techniques for getting ready for generation (moreover for support and repair). These generally incorporate consolidating diverse machine segments into one discrete part, and doing the making, (for instance, throwing, stamping, and machining) for numerous segments in one setup with one machine arrange framework (of a machine instrument or other bit of assembling hardware). These yields bring down unit cost of generation (as well as upkeep and repair). Today most motors for automobiles, trucks, transports, tractors, so on are worked with reasonably very coordinated plan, so the words "mono square" and "en piece" are every now and then used as a piece of portraying them; such developments is much of the time certain. Along these lines "motor piece", "barrel square", or essentially "square" are the terms at risk to be heard in the carport or in the city.
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A Review on Thermal Analysis of Engine Cylinder Block with Fin using modified geometry

A Review on Thermal Analysis of Engine Cylinder Block with Fin using modified geometry

Ajay Paul et.al.[3] Carried out Numerical Simulations to determine heat transfer characteristics of different fin parameters namely, number of fins, fin thickness at varying air velocities. A cylinder with a single fin mounted and explained it was tested experimentally. The numerical simulation of the same setup was done using CFD. Cylinders with fins of 4 mm and 6 mm thickness were simulated for 1, 3, 4 & 6 fin configurations. They concluded that 1. When fin thickness was increased, the reduced gap between the fins resulted in swirls being created which helped in increasing the heat transfer. 2. Large number of fins with less thickness can be preferred in high speed vehicles than thick fins with less numbers as it helps inducing greater turbulence and hence higher heat transferrin.
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Thermal Analysis and Optimization of Two Wheeler Engine Cylinder Fins

Thermal Analysis and Optimization of Two Wheeler Engine Cylinder Fins

dissipate heat generated in the engine. Various automobile industries work to increase this heat dissipation rate by which engine efficiency can be increased. The heat generated during combustion in IC engine should be maintained at higher level to increase thermal efficiency, but to prevent the thermal damage some heat should remove from the engine. In air- cooled engine, extended surfaces called fins are provided at the periphery of engine cylinder to increase heat transfer rate. That is why the analysis of fin is important to increase the heat transfer rate. The main aim of the paper is to analyse the thermal properties by varying geometry and thickness of cylinder fins. To improve the rate of heat transfer thermal analysis of two designs providing slot, reducing the fin thickness and increasing no. of fins is carried out in this paper. The cylinder block with fins are modelled and analysis is done in CAD and FEA software.
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A study of bubble entrainment as related to runner velocity in aluminum sand castings using the Cosworth process.

A study of bubble entrainment as related to runner velocity in aluminum sand castings using the Cosworth process.

Figure A25: MAGMA 3.0L cylinder block Jill simulation-current runner@ 3.2 seconds; Initial Transient is more than halfway down the runner's length. V IT remains at approx[r]

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Design and Analysis of Cylinder and Cylinder head of 4-stroke SI Engine for weight reduction

Design and Analysis of Cylinder and Cylinder head of 4-stroke SI Engine for weight reduction

The hard chrome plating on cylinder block of Aluminum alloy is done through electroplating deposition. In this process cylinder blocks are made cathode & the anode, usually made of lead (Pb), acid solution. The dimension of the anode depends on the bore diameter & stroke length of cylinder block. The thickness of coating is controlled by knowing the total surface area of the cylinder bore & adjusting the current density. It has been reported that a coating thickness of 60-70 microns on bore surface of Aluminum cylinder block gives better fuel efficiency & thermal conductivity in comparison with Cast Iron cylinder blocks or Aluminum barrel fitted with Cast Iron liner.
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Laboratory Testing of a MEMS Sensor System for In-Situ Monitoring of the Engineered Barrier in a Geological Disposal Facility

Laboratory Testing of a MEMS Sensor System for In-Situ Monitoring of the Engineered Barrier in a Geological Disposal Facility

Experiment 1 focuses on verifying the mechanical robustness of the RH sensor under the swelling pressure exerted by hydrated bentonite. The test was carried out in an engineered oedometer cell, specifically designed by the Universitat Politecnica de Catalunya, as shown in Figure 3. The oedometer cell is separated into two sections by a ceramic-disc-supported thin membrane. On top of the membrane an enclosed water reservoir is used to apply a known vertical stress to the top of the sample within the range 0 – 2 MPa. A compacted bentonite block was fitted in the cavity below the membrane. The compacted MX-80 bentonite was drilled to form a 20mm-thick cylinder block, with a diameter of 50mm. The size of the bentonite block corresponded exactly to the dimension of the cavity inside the oedometer cell, in order to ensure that the top surface of the bentonite block was in firm contact with the membrane.
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EXPERIMENTAL & NUMERICAL STUDY OF NATURAL CONVECTION IN ENGINE BLOCK

EXPERIMENTAL & NUMERICAL STUDY OF NATURAL CONVECTION IN ENGINE BLOCK

In this project experiments were conducted to study natural convection in three different engine blocks. Current study uses three engine blocks machined from plain Aluminium. Plain Cylinder Block, Cylinder Block with fins & Square Block with fins is used. Inside the cylinder block fine heaters were fitted to mimic heating at different locations. Temperatures at various locations were measured. Few experimental data is compared with CFD results by Fluent.

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Vol 3, No 9 (2015)

Vol 3, No 9 (2015)

As shown in fig, this type of liner is made in the shape of a barrel with flange at the top which keeps it into position. The entire outer surface bears against the cylinder block casting and hence has to be machined very accurately both from the inside and the outside. It is put in position by shrinking the liner. This introduces some stresses due to shrinkage and hence the liner bore has to be machined accurately again after the liner has been put into the cylinder casting. Too loose a liner will result in poor heat dissipation because of absence of a good contact with the cylinder block. This will result in higher operating temperatures. If the lubrication is also deficient, it may cause scuffing. Too tight a liner is even worse than the too loose case. It produces distortion of cylinder block, liner cracking, hot spots and scuffing. Even if a correct liner is fitted in a cylinder block which itself is badly distorted, it will result in poor sealing action of rings if the liner is thin because then it will also tend to adopt the shape of the distorted block in which it is fitted. Even if the liner is thick enough to resist change of shape, there will be some hot spots which will lead to scuffing on the inner surface of the liner.
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Creating Entrepreneurship in Skill based Educational Institutes in Western Maharashtra

Creating Entrepreneurship in Skill based Educational Institutes in Western Maharashtra

reinforced in aluminium alloy (Al-2024) composite samples. From the literature review it is observed that by implementing aluminium metal matrix composites instead of grey cast iron for IC engine cylinder block, the engine efficiency is improved. Also fuel economy is achieved due to reduction of engine weight. Most of the researchers concentrate on the aluminium metal matrix composites for manufacturing of IC engine cylinder block. Based on various reviews this project concentrates on aluminium metal matrix composites.

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