US20120210578A1 - Method Of Manufacturing An Engine Block - Google Patents
Method Of Manufacturing An Engine Block Download PDFInfo
- Publication number
- US20120210578A1 US20120210578A1 US13/462,914 US201213462914A US2012210578A1 US 20120210578 A1 US20120210578 A1 US 20120210578A1 US 201213462914 A US201213462914 A US 201213462914A US 2012210578 A1 US2012210578 A1 US 2012210578A1
- Authority
- US
- United States
- Prior art keywords
- engine block
- insert
- top deck
- recessed area
- cylinder bore
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 11
- 239000012530 fluid Substances 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 23
- 239000000463 material Substances 0.000 claims abstract description 22
- 238000003754 machining Methods 0.000 claims description 9
- 230000000295 complement effect Effects 0.000 claims description 2
- 238000002485 combustion reaction Methods 0.000 abstract description 11
- 230000008439 repair process Effects 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 230000003628 erosive effect Effects 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- 230000035882 stress Effects 0.000 description 3
- 239000002826 coolant Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000002452 interceptive effect Effects 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 238000011179 visual inspection Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
- B23P6/02—Pistons or cylinders
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49231—I.C. [internal combustion] engine making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49229—Prime mover or fluid pump making
- Y10T29/49231—I.C. [internal combustion] engine making
- Y10T29/49233—Repairing, converting, servicing or salvaging
Definitions
- the present disclosure relates generally to a method of manufacturing an engine block. More particularly, the present disclosure relates to removing engine block material surrounding a cylinder bore and adjacent fluid passages to create a recessed area, and positioning an insert within the recessed area.
- One such component is the engine block, which may experience loads from combustion events occurring within combustion chambers formed by the cylinder head, pistons, and cylinder bores of the engine block. These events may subject the engine block to high loads and stresses, including thermal stresses and mechanical stresses, which may be transmitted to the engine block at, among other locations, the cylinder head, which is mounted to a top deck of the engine block, and the cylinder bores. As a result of these stresses, small cracks may form, or general wear may occur, within the engine block, particularly within or near the cylinder bores at the top deck of the engine block. In addition, wear and erosion may occur along edges of fluid passages surrounding the cylinder bores and opening through the top deck.
- U.S. Pat. No. 5,222,295 teaches a method for repairing diesel engine cylinder blocks. Specifically, the cited reference teaches a method for removing selected portions along the longitudinal axis of a cylinder bore of the engine block, and installing inserts within the cavities formed within the cylinder bore. Although the described method may adequately repair cracks occurring within the cylinder bore, the reference does not contemplate cracks that may radiate from the cylinder bore and across the top deck of the engine block, or that may occur along edges of the surrounding water passages. Additionally, there remains a continuing need for methods of engine block repair and remanufacture that are effective and economically feasible.
- the present disclosure is directed to one or more of the problems set forth above.
- a method for manufacturing an engine block includes a step of removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area. Material is also removed from the top deck of the engine block surrounding at least one fluid passage to create a second removal area. An insert is positioned within a recessed area defined by the first removal area and the second removal area.
- an engine block for an internal combustion engine includes a top deck. At least one cylinder bore is formed within the engine block and opens through the top deck. At least one fluid passage is also formed within the engine block and opens through the top deck. An insert is positioned within a recessed area, surrounding both the cylinder bore and the fluid passage, of the top deck.
- an insert for an engine block includes a ring-shaped body having an inner diameter matching a diameter of a cylinder bore of an engine block.
- a plurality of arcuate segments extend radially from an outer edge of the ring-shaped body.
- Each of the arcuate segments includes an opening therethrough having a diameter matching a diameter of a fluid passage of the engine block.
- FIG. 1 is a perspective view of an engine block, according to the present disclosure
- FIG. 2 is a plan view of a top deck of the engine block of FIG. 1 , depicting exemplary cracks that may form near a cylinder bore and adjacent fluid passages;
- FIG. 3 is an additional plan view of the top deck, depicting a recessed area surrounding the cylinder bore and adjacent fluid passages;
- FIG. 4 is an additional plan view of the top deck, depicting an insert positioned within the recessed area of FIG. 3 ;
- FIG. 5 is a perspective view of the insert of FIG. 4 .
- FIG. 1 An exemplary embodiment of an engine block 10 , also referred to as a cylinder block, is shown generally in FIG. 1 .
- the engine block 10 may, for example, be constructed of cast iron or, alternatively, aluminum or magnesium, or any other desirable material, and may include one or more cylindrically bored holes for receiving pistons of an internal combustion engine, such as a compression ignition engine or a spark-ignited engine. It should be appreciated that such an internal combustion engine, which includes engine block 10 , may be used to power an on-highway or off-highway machine, stationary equipment, or any other known machine or vehicle.
- the engine block 10 may be a one-piece casting and may generally include an upper section 12 and a lower section 14 .
- the upper section 12 may include a plurality of cylinder bores 16 formed within the engine block 10 and opening through a top deck 18 of the engine block 10 .
- six cylinder bores 16 are shown, it should be appreciated that the engine block 10 may include any number of cylinder bores 16 , each of which may or may not include a cylinder liner.
- a cylinder head (not shown) may be attached to the engine block 10 , such as, for example, by using a plurality of attachment bolts that may be threadably received within a corresponding number of attachment bores 20 .
- the cylinder head may seal each of the cylinder bores 16 , thus creating combustion chambers therein, and may provide a structure for supporting intake and exhaust valves and/or ports, fuel injectors, necessary linkages, and/or other known devices or structures.
- the upper section 12 of the engine block 10 may also include a plurality of fluid passages 22 , such as water passages, circumferentially spaced about each cylinder bore 16 . Although eight fluid passages 22 are shown, it should be appreciated that any number of fluid passages 22 may be provided throughout the engine block 10 . Each fluid passage 22 may be formed within the engine block 10 and may open through the top deck 18 , as shown. It should be appreciated that the fluid passages 22 , and additional fluid passages and/or chambers within the engine block 10 , may form a water jacket or other similar cooling system for controlling circulation of a coolant and providing proper cooling of the engine block 10 . It should also be appreciated that the fluid passages 22 , which may include ferrule type coolant directors, and/or the water jacket may be configured to provide cooling of the cylinder head, or components thereof, attached to the engine block 10 .
- the lower section 14 of the engine block 10 may also include and/or define a portion of the water jacket described above.
- the lower section 14 may be of conventional form, and may include a crankcase, in which a crankshaft rotates.
- the lower section 14 of the engine block 10 as well as the cylinder head and the internal combustion engine, in general, are not within the scope of the present disclosure and, therefore, will not be described herein in greater detail. It should be appreciated, however, that the engine block 10 , including features described herein, is contemplated for use with any type and/or configuration of internal combustion engine.
- FIG. 2 a portion of the top deck 18 of the engine block 10 is shown. Particularly, one of cylinder bores 16 and adjacent, or surrounding, fluid passages 22 are shown, along with cracks that may occur within the top deck 18 .
- one or more cracks may form within the top deck 18 of the engine block 10 , as should be appreciated by those skilled in the art.
- a crack 30 may form within the cylinder bore 16 , shown with a cylinder liner 32 disposed therein, and may radiate therefrom along the top deck 18 of the engine block 10 .
- such a crack may extend to one of the fluid passages 22 , as shown at 34 .
- a crack 36 may form within one of the fluid passages 22 and may extend therefrom across the top deck 18 of the engine block 10 . Wear or erosion may also occur at edges of the fluid passages 22 along the top deck 18 . Additional cracks, such as crack 38 , and/or wear may occur within the top deck 18 of the engine block 10 , as should be appreciated by those skilled in the art.
- engine block material may be removed from the top deck 18 of the engine block 10 .
- “manufacturing” may refer broadly to the original manufacture, remanufacture, repair, or other similar process associated with the engine block 10 .
- engine block material which may include one or more of the cracks 30 , 34 , 36 , and 38 shown in FIG. 2 , may be removed from the engine block 10 .
- engine block material surrounding the cylinder bore 16 may be removed to create a first removal area 50 , as shown in FIG. 3 .
- engine block material may be removed from the top deck 18 of the engine block 10 surrounding at least one of the fluid passages 22 to create a second removal area 52 .
- engine block material may be removed from the top deck 18 surrounding each of the plurality of fluid passages 22 , resulting in a corresponding number of second removal areas 52 .
- Material may be removed from the top deck 18 of the engine block 10 using any known machining process, such as, for example, milling or grinding, to create the first and second removal areas 50 and 52 . Further, the first and second removal areas 50 and 52 may be created using a manual and/or automatic process. According to one embodiment, for example, a machining tool used to remove material from the engine block 10 may be operated via computer numerical control (CNC). However, any useful tool for removing engine block material according to precise specifications is contemplated.
- CNC computer numerical control
- a recessed area 54 may be defined by the first removal area 50 and the plurality of second removal areas 52 .
- the recessed area 54 may include a predetermined depth sufficient to machine out cracks and/or defects within the engine block 10 , such as cracks 30 , 34 , 36 , and 38 , described with reference to FIG. 2 .
- the recessed area 54 may also extend radially from each of the cylinder bore 16 , or cylinder liner 32 , and the fluid passages 22 an amount sufficient to remove most cracks or defects, without interfering with attachment bores 20 , other passages or chambers of the water jacket, or the like. It should be appreciated that the specific dimensions for the recessed area 54 may vary, depending on the configuration of the engine block 10 , and/or the repairs being performed.
- the insert 60 may generally include a ring-shaped body 62 having a central opening 64 matching, or aligned with, the cylinder bore 16 .
- the insert 60 may also include a plurality of arcuate segments 66 extending radially from an outer edge 68 of the ring-shaped body 62 .
- Each of the plurality of arcuate segments 66 may include an opening 70 matching, or aligned with, a corresponding one of the plurality of fluid passages 22 .
- “matching,” as used herein, may generally refer to openings that are substantially aligned or, at least, partially overlapping.
- the insert 60 may be retained within the recessed area 54 using any known retention means, including, according to one embodiment, an interference fit.
- the insert 60 may be machined, such as using a CNC process, to include dimensions slightly larger than dimensions of the recessed area 54 , such that the insert 60 may be press fit within the corresponding portion of the top deck 18 .
- the ring-shaped body 62 may include eight radially extending arcuate segments 66 , corresponding to eight fluid passages 22 of the engine block 10 .
- the eight radially extending arcuate segments 66 may be unevenly spaced about a circumference of the insert 60 .
- the insert 60 may include any number of arcuate segments 66 that may or may not be evenly spaced about the circumference of the insert 60 , depending on the specific configuration of the engine block 10 .
- the insert 60 may also include a keyed feature 72 positioned along the outer edge 68 of the ring-shaped body 62 .
- the keyed feature 72 may be useful to properly position the insert 60 within the recessed area 54 .
- the keyed feature 72 of the insert 60 may be aligned with a complementary keyed feature 74 of the recessed area 54 , shown in FIG. 3 , prior to press fitting the insert 60 into the top deck 18 .
- the insert 60 may be made from stainless steel, or any other useful material, and may include a substantially uniform thickness. As should be appreciated, the thickness, as well as other dimensions of the insert 60 , may be determined based on the dimensions of the recessed area 54 . According to one embodiment, it may be desirable to provide an insert 60 having a thickness such that a top portion of the insert 60 will extend beyond a planar surface of the top deck 18 . After positioning the insert 60 within the recessed area 54 , a machining tool may be used to plane the surface of the top deck 18 , thus removing any excess portions of the insert 60 . Such a procedure may ensure a substantially planar surface of the top deck 18 after the insert 60 has been positioned within the recessed area 54 .
- cracks such as cracks formed within or radiating from the recessed area 54
- the presently disclosed method, as described herein, may be repeated to repair such cracks.
- the insert 60 may be removed, such as by creating one or more threaded bores within the insert 60 to attach a removal tool, and the additional cracks and/or wear occurring near the cylinder bore 16 and fluid passages 22 may be machined out.
- the recessed area 54 including both the first removal area 50 and second removal areas 52 , may be enlarged only an amount sufficient to remove most of the cracks and/or wear, without interfering with other structures or components of the engine block 10 .
- the engine block 10 may be limited to a finite number of repairs.
- an appropriately dimensioned insert 60 may be press fit within the recessed area 54 .
- the present disclosure finds potential applicability to any engine block that may be subject to operational loads causing cracks and/or wear. Further, the disclosure may be specifically applicable to engine blocks having cracks radiating from cylinder bores and extending across a top deck of the engine block. Yet further, the present disclosure may be applicable to fluid passages surrounding such cylinder bores that may be subject to general wear and/or erosion. Although the disclosure describes the remanufacture, or repair, of such engine blocks, the method described herein may also be used during manufacture to reduce the occurrence of such cracks and/or wear during operation.
- an engine block 10 may include a plurality of cylinder bores 16 formed within the engine block 10 and opening through a top deck 18 of the engine block 10 .
- the engine block 10 may also include a plurality of fluid passages 22 , such as water passages, circumferentially spaced about each cylinder bore 16 .
- Each fluid passage 22 may be formed within the engine block 10 and may open through the top deck 18 , as shown in FIG. 1 .
- the engine block 10 may also include a water jacket, or other suitable chamber, at least partially surrounding the cylinder bores 16 , and other useful components known in the art.
- the engine block 10 may be inspected for cracks, such as by visual inspection or using a magneflux check or other known means. Cracks, such as cracks 30 , 34 , 36 , and 38 , may be discovered during the inspection. Additionally, one or more of the fluid passages 22 may exhibit wear and/or erosion around the openings thereof, along the top deck 18 of the engine block 10 . To repair the engine block 10 , material from the top deck 18 of the engine block 10 surrounding the cylinder bore 16 may be removed to create a first removal area 50 , as shown in FIG. 3 .
- Material may also be removed from the top deck 18 of the engine block 10 surrounding at least one fluid passage 22 , and preferably a plurality of fluid passages 22 , to create one or more second removal areas 52 .
- the first removal area 50 and the one or more second removal areas 52 may define a recessed area 54 .
- An insert 60 may be press fit, or otherwise positioned, within the recessed area 54 .
- the insert 60 may be properly dimensioned, such as by using a CNC machining process, to fit within the recessed area 54 .
- the insert 60 may include a substantially ring-shaped body 62 having a central opening 64 matching, or aligned with, the cylinder bore 16 .
- the insert 60 may also include a plurality of arcuate segments 66 extending radially from an outer edge 68 of the ring-shaped body 62 , and including openings 70 therethrough, matching, or aligned with, a corresponding one of the plurality of fluid passages 22 .
- the presently disclosed method may provide an effective means for repairing cracks and/or wear occurring within an engine block, particularly at or near a cylinder bore and surrounding water passages.
- the present disclosure may be implemented during manufacture of an engine block to reduce the occurrence of such cracks and/or wear.
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- Engineering & Computer Science (AREA)
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- Cylinder Crankcases Of Internal Combustion Engines (AREA)
Abstract
A method for manufacturing an engine block, such as for an internal combustion engine, includes a step of removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area. Material is also removed from the top deck of the engine block surrounding at least one fluid passage to create a second removal area. An insert is positioned within a recessed area defined by the first removal area and the second removal area.
Description
- This patent application is a divisional of U.S. patent application Ser. No. 12/217,462, filed Jul. 3, 2008.
- The present disclosure relates generally to a method of manufacturing an engine block. More particularly, the present disclosure relates to removing engine block material surrounding a cylinder bore and adjacent fluid passages to create a recessed area, and positioning an insert within the recessed area.
- Many components of an internal combustion engine are subject to high loads and wear during operation of the engine. One such component, for example, is the engine block, which may experience loads from combustion events occurring within combustion chambers formed by the cylinder head, pistons, and cylinder bores of the engine block. These events may subject the engine block to high loads and stresses, including thermal stresses and mechanical stresses, which may be transmitted to the engine block at, among other locations, the cylinder head, which is mounted to a top deck of the engine block, and the cylinder bores. As a result of these stresses, small cracks may form, or general wear may occur, within the engine block, particularly within or near the cylinder bores at the top deck of the engine block. In addition, wear and erosion may occur along edges of fluid passages surrounding the cylinder bores and opening through the top deck.
- U.S. Pat. No. 5,222,295 teaches a method for repairing diesel engine cylinder blocks. Specifically, the cited reference teaches a method for removing selected portions along the longitudinal axis of a cylinder bore of the engine block, and installing inserts within the cavities formed within the cylinder bore. Although the described method may adequately repair cracks occurring within the cylinder bore, the reference does not contemplate cracks that may radiate from the cylinder bore and across the top deck of the engine block, or that may occur along edges of the surrounding water passages. Additionally, there remains a continuing need for methods of engine block repair and remanufacture that are effective and economically feasible.
- The present disclosure is directed to one or more of the problems set forth above.
- In one aspect, a method for manufacturing an engine block includes a step of removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area. Material is also removed from the top deck of the engine block surrounding at least one fluid passage to create a second removal area. An insert is positioned within a recessed area defined by the first removal area and the second removal area.
- In another aspect, an engine block for an internal combustion engine includes a top deck. At least one cylinder bore is formed within the engine block and opens through the top deck. At least one fluid passage is also formed within the engine block and opens through the top deck. An insert is positioned within a recessed area, surrounding both the cylinder bore and the fluid passage, of the top deck.
- In yet another aspect, an insert for an engine block includes a ring-shaped body having an inner diameter matching a diameter of a cylinder bore of an engine block. A plurality of arcuate segments extend radially from an outer edge of the ring-shaped body. Each of the arcuate segments includes an opening therethrough having a diameter matching a diameter of a fluid passage of the engine block.
-
FIG. 1 is a perspective view of an engine block, according to the present disclosure; -
FIG. 2 is a plan view of a top deck of the engine block ofFIG. 1 , depicting exemplary cracks that may form near a cylinder bore and adjacent fluid passages; -
FIG. 3 is an additional plan view of the top deck, depicting a recessed area surrounding the cylinder bore and adjacent fluid passages; -
FIG. 4 is an additional plan view of the top deck, depicting an insert positioned within the recessed area ofFIG. 3 ; and -
FIG. 5 is a perspective view of the insert ofFIG. 4 . - An exemplary embodiment of an
engine block 10, also referred to as a cylinder block, is shown generally inFIG. 1 . Theengine block 10 may, for example, be constructed of cast iron or, alternatively, aluminum or magnesium, or any other desirable material, and may include one or more cylindrically bored holes for receiving pistons of an internal combustion engine, such as a compression ignition engine or a spark-ignited engine. It should be appreciated that such an internal combustion engine, which includesengine block 10, may be used to power an on-highway or off-highway machine, stationary equipment, or any other known machine or vehicle. - The
engine block 10 may be a one-piece casting and may generally include anupper section 12 and alower section 14. Theupper section 12 may include a plurality ofcylinder bores 16 formed within theengine block 10 and opening through atop deck 18 of theengine block 10. Although sixcylinder bores 16 are shown, it should be appreciated that theengine block 10 may include any number ofcylinder bores 16, each of which may or may not include a cylinder liner. A cylinder head (not shown) may be attached to theengine block 10, such as, for example, by using a plurality of attachment bolts that may be threadably received within a corresponding number ofattachment bores 20. The cylinder head, as is known in the art, may seal each of thecylinder bores 16, thus creating combustion chambers therein, and may provide a structure for supporting intake and exhaust valves and/or ports, fuel injectors, necessary linkages, and/or other known devices or structures. - The
upper section 12 of theengine block 10 may also include a plurality offluid passages 22, such as water passages, circumferentially spaced about each cylinder bore 16. Although eightfluid passages 22 are shown, it should be appreciated that any number offluid passages 22 may be provided throughout theengine block 10. Eachfluid passage 22 may be formed within theengine block 10 and may open through thetop deck 18, as shown. It should be appreciated that thefluid passages 22, and additional fluid passages and/or chambers within theengine block 10, may form a water jacket or other similar cooling system for controlling circulation of a coolant and providing proper cooling of theengine block 10. It should also be appreciated that thefluid passages 22, which may include ferrule type coolant directors, and/or the water jacket may be configured to provide cooling of the cylinder head, or components thereof, attached to theengine block 10. - The
lower section 14 of theengine block 10 may also include and/or define a portion of the water jacket described above. Thelower section 14 may be of conventional form, and may include a crankcase, in which a crankshaft rotates. Thelower section 14 of theengine block 10, as well as the cylinder head and the internal combustion engine, in general, are not within the scope of the present disclosure and, therefore, will not be described herein in greater detail. It should be appreciated, however, that theengine block 10, including features described herein, is contemplated for use with any type and/or configuration of internal combustion engine. - Turning now to
FIG. 2 , a portion of thetop deck 18 of theengine block 10 is shown. Particularly, one ofcylinder bores 16 and adjacent, or surrounding,fluid passages 22 are shown, along with cracks that may occur within thetop deck 18. Specifically, during operation of an internal combustion engine that includesengine block 10, or even during the original manufacture thereof, one or more cracks may form within thetop deck 18 of theengine block 10, as should be appreciated by those skilled in the art. For example, acrack 30 may form within thecylinder bore 16, shown with acylinder liner 32 disposed therein, and may radiate therefrom along thetop deck 18 of theengine block 10. According to one embodiment, such a crack may extend to one of thefluid passages 22, as shown at 34. Similarly, acrack 36 may form within one of thefluid passages 22 and may extend therefrom across thetop deck 18 of theengine block 10. Wear or erosion may also occur at edges of thefluid passages 22 along thetop deck 18. Additional cracks, such ascrack 38, and/or wear may occur within thetop deck 18 of theengine block 10, as should be appreciated by those skilled in the art. - During a manufacturing process of the
engine block 10, material from thetop deck 18 of theengine block 10 may be removed. As used herein, “manufacturing” may refer broadly to the original manufacture, remanufacture, repair, or other similar process associated with theengine block 10. Specifically, engine block material, which may include one or more of thecracks FIG. 2 , may be removed from theengine block 10. According to one embodiment, engine block material surrounding thecylinder bore 16 may be removed to create afirst removal area 50, as shown inFIG. 3 . In addition, engine block material may be removed from thetop deck 18 of theengine block 10 surrounding at least one of thefluid passages 22 to create asecond removal area 52. Preferably, and as shown in the referenced Figure, engine block material may be removed from thetop deck 18 surrounding each of the plurality offluid passages 22, resulting in a corresponding number ofsecond removal areas 52. - Material may be removed from the
top deck 18 of theengine block 10 using any known machining process, such as, for example, milling or grinding, to create the first andsecond removal areas second removal areas engine block 10 may be operated via computer numerical control (CNC). However, any useful tool for removing engine block material according to precise specifications is contemplated. - A recessed
area 54, as shown inFIG. 3 , may be defined by thefirst removal area 50 and the plurality ofsecond removal areas 52. The recessedarea 54, as should be appreciated, may include a predetermined depth sufficient to machine out cracks and/or defects within theengine block 10, such ascracks FIG. 2 . The recessedarea 54 may also extend radially from each of the cylinder bore 16, orcylinder liner 32, and thefluid passages 22 an amount sufficient to remove most cracks or defects, without interfering with attachment bores 20, other passages or chambers of the water jacket, or the like. It should be appreciated that the specific dimensions for the recessedarea 54 may vary, depending on the configuration of theengine block 10, and/or the repairs being performed. - Turning now to
FIG. 4 , aninsert 60 is shown positioned within the recessedarea 54. Theinsert 60, also shown inFIG. 5 , may generally include a ring-shapedbody 62 having acentral opening 64 matching, or aligned with, the cylinder bore 16. Theinsert 60 may also include a plurality ofarcuate segments 66 extending radially from anouter edge 68 of the ring-shapedbody 62. Each of the plurality ofarcuate segments 66 may include anopening 70 matching, or aligned with, a corresponding one of the plurality offluid passages 22. It should be appreciated that “matching,” as used herein, may generally refer to openings that are substantially aligned or, at least, partially overlapping. It should be also appreciated that theinsert 60 may be retained within the recessedarea 54 using any known retention means, including, according to one embodiment, an interference fit. Specifically, theinsert 60 may be machined, such as using a CNC process, to include dimensions slightly larger than dimensions of the recessedarea 54, such that theinsert 60 may be press fit within the corresponding portion of thetop deck 18. - According to a specific embodiment, the ring-shaped
body 62 may include eight radially extendingarcuate segments 66, corresponding to eightfluid passages 22 of theengine block 10. The eight radially extendingarcuate segments 66 may be unevenly spaced about a circumference of theinsert 60. It should be appreciated, however, that theinsert 60 may include any number ofarcuate segments 66 that may or may not be evenly spaced about the circumference of theinsert 60, depending on the specific configuration of theengine block 10. According to the exemplary embodiment, theinsert 60 may also include akeyed feature 72 positioned along theouter edge 68 of the ring-shapedbody 62. Thekeyed feature 72, depicted as a protrusion extending radially from theouter edge 68 of the ring-shapedbody 62 between two of thearcuate segments 66, may be useful to properly position theinsert 60 within the recessedarea 54. For example, thekeyed feature 72 of theinsert 60 may be aligned with a complementary keyedfeature 74 of the recessedarea 54, shown inFIG. 3 , prior to press fitting theinsert 60 into thetop deck 18. - The
insert 60 may be made from stainless steel, or any other useful material, and may include a substantially uniform thickness. As should be appreciated, the thickness, as well as other dimensions of theinsert 60, may be determined based on the dimensions of the recessedarea 54. According to one embodiment, it may be desirable to provide aninsert 60 having a thickness such that a top portion of theinsert 60 will extend beyond a planar surface of thetop deck 18. After positioning theinsert 60 within the recessedarea 54, a machining tool may be used to plane the surface of thetop deck 18, thus removing any excess portions of theinsert 60. Such a procedure may ensure a substantially planar surface of thetop deck 18 after theinsert 60 has been positioned within the recessedarea 54. - It should be appreciated that cracks, such as cracks formed within or radiating from the recessed
area 54, may occur after repair. The presently disclosed method, as described herein, may be repeated to repair such cracks. Specifically, theinsert 60 may be removed, such as by creating one or more threaded bores within theinsert 60 to attach a removal tool, and the additional cracks and/or wear occurring near the cylinder bore 16 andfluid passages 22 may be machined out. However, the recessedarea 54, including both thefirst removal area 50 andsecond removal areas 52, may be enlarged only an amount sufficient to remove most of the cracks and/or wear, without interfering with other structures or components of theengine block 10. As such, theengine block 10 may be limited to a finite number of repairs. After the additional engine block material has been removed, an appropriately dimensionedinsert 60 may be press fit within the recessedarea 54. - The present disclosure finds potential applicability to any engine block that may be subject to operational loads causing cracks and/or wear. Further, the disclosure may be specifically applicable to engine blocks having cracks radiating from cylinder bores and extending across a top deck of the engine block. Yet further, the present disclosure may be applicable to fluid passages surrounding such cylinder bores that may be subject to general wear and/or erosion. Although the disclosure describes the remanufacture, or repair, of such engine blocks, the method described herein may also be used during manufacture to reduce the occurrence of such cracks and/or wear during operation.
- Turning now to
FIGS. 1-5 , anengine block 10, as described above, may include a plurality of cylinder bores 16 formed within theengine block 10 and opening through atop deck 18 of theengine block 10. Theengine block 10 may also include a plurality offluid passages 22, such as water passages, circumferentially spaced about each cylinder bore 16. Eachfluid passage 22 may be formed within theengine block 10 and may open through thetop deck 18, as shown inFIG. 1 . Theengine block 10 may also include a water jacket, or other suitable chamber, at least partially surrounding the cylinder bores 16, and other useful components known in the art. - During remanufacture, or repair, the
engine block 10 may be inspected for cracks, such as by visual inspection or using a magneflux check or other known means. Cracks, such ascracks fluid passages 22 may exhibit wear and/or erosion around the openings thereof, along thetop deck 18 of theengine block 10. To repair theengine block 10, material from thetop deck 18 of theengine block 10 surrounding the cylinder bore 16 may be removed to create afirst removal area 50, as shown inFIG. 3 . Material may also be removed from thetop deck 18 of theengine block 10 surrounding at least onefluid passage 22, and preferably a plurality offluid passages 22, to create one or moresecond removal areas 52. Thefirst removal area 50 and the one or moresecond removal areas 52 may define a recessedarea 54. - An
insert 60 may be press fit, or otherwise positioned, within the recessedarea 54. As such, theinsert 60 may be properly dimensioned, such as by using a CNC machining process, to fit within the recessedarea 54. According to the exemplary embodiment, theinsert 60 may include a substantially ring-shapedbody 62 having acentral opening 64 matching, or aligned with, the cylinder bore 16. Theinsert 60 may also include a plurality ofarcuate segments 66 extending radially from anouter edge 68 of the ring-shapedbody 62, and includingopenings 70 therethrough, matching, or aligned with, a corresponding one of the plurality offluid passages 22. - The presently disclosed method may provide an effective means for repairing cracks and/or wear occurring within an engine block, particularly at or near a cylinder bore and surrounding water passages. Alternatively, the present disclosure may be implemented during manufacture of an engine block to reduce the occurrence of such cracks and/or wear.
- It should be understood that the above description is intended for illustrative purposes only, and is not intended to limit the scope of the present disclosure in any way. Thus, those skilled in the art will appreciate that other aspects of the disclosure can be obtained from a study of the drawings, the disclosure and the appended claims.
Claims (10)
1. A method for manufacturing an engine block, comprising:
removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area;
removing material from the top deck of the engine block surrounding at least one fluid passage to create a second removal area; and
positioning an insert within a recessed area defined by the first removal area and the second removal area.
2. The method of claim 1 , wherein the second removing step includes removing material from the top deck of the engine block surrounding each of a plurality of fluid passages circumferentially spaced about the cylinder bore.
3. The method of claim 1 , wherein at least one of the first removing step and the second removing step includes machining out a crack within the engine block.
4. The method of claim 3 , wherein at least one of the first removing step and the second removing step further includes machining out the crack radiating from the cylinder bore.
5. The method of claim 3 , wherein at least one of the first removing step and the second removing step further includes machining out the crack radiating from the at least one fluid passage.
6. The method of claim 1 , wherein the positioning step includes press fitting the insert within the recessed area.
7. The method of claim 6 , wherein the positioning step further includes aligning a keyed feature of the insert with a complementary keyed feature of the recessed area prior to the press fitting step.
8. The method of claim 6 , further including machining the insert to a thickness greater than a depth of the recessed area.
9. The method of claim 8 , further including planing the top deck of the engine block after the press fitting step.
10. The method of claim 1 , wherein the first removing step and the second removing step include removing the material using a computer numerical control machining tool.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/462,914 US20120210578A1 (en) | 2008-07-03 | 2012-05-03 | Method Of Manufacturing An Engine Block |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/217,462 US8191529B2 (en) | 2008-07-03 | 2008-07-03 | Method of manufacturing an engine block |
US13/462,914 US20120210578A1 (en) | 2008-07-03 | 2012-05-03 | Method Of Manufacturing An Engine Block |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US12/217,462 Division US8191529B2 (en) | 2008-07-03 | 2008-07-03 | Method of manufacturing an engine block |
Publications (1)
Publication Number | Publication Date |
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US20120210578A1 true US20120210578A1 (en) | 2012-08-23 |
Family
ID=41463236
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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US12/217,462 Active 2031-04-05 US8191529B2 (en) | 2008-07-03 | 2008-07-03 | Method of manufacturing an engine block |
US13/462,914 Abandoned US20120210578A1 (en) | 2008-07-03 | 2012-05-03 | Method Of Manufacturing An Engine Block |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US12/217,462 Active 2031-04-05 US8191529B2 (en) | 2008-07-03 | 2008-07-03 | Method of manufacturing an engine block |
Country Status (4)
Country | Link |
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US (2) | US8191529B2 (en) |
CN (1) | CN102084113B (en) |
DE (1) | DE112009001596B4 (en) |
WO (1) | WO2010003067A2 (en) |
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WO2014093667A3 (en) * | 2012-12-13 | 2014-11-13 | Caterpillar Inc. | Method of manufacturing an engine block |
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US20120304646A1 (en) * | 2011-05-31 | 2012-12-06 | Leonard Paul Palmisano | Method and apparatus for repairing an engine component |
US8714131B2 (en) | 2011-09-30 | 2014-05-06 | Caterpillar Inc. | Method of manufacturing an engine block |
CN102430896A (en) * | 2011-10-24 | 2012-05-02 | 东风汽车股份有限公司 | Engine cylinder block sand outlet processing technology |
US8726874B2 (en) * | 2012-05-01 | 2014-05-20 | Ford Global Technologies, Llc | Cylinder bore with selective surface treatment and method of making the same |
US9511467B2 (en) | 2013-06-10 | 2016-12-06 | Ford Global Technologies, Llc | Cylindrical surface profile cutting tool and process |
JP6068752B2 (en) * | 2013-12-10 | 2017-01-25 | 本田技研工業株式会社 | Internal combustion engine for saddle-ride type vehicles |
US9382871B2 (en) * | 2014-01-30 | 2016-07-05 | Caterpillar Inc. | Method for repair of cylinder block including water ferrule |
US20160265475A1 (en) * | 2015-03-11 | 2016-09-15 | Caterpillar Inc. | Cylinder Head/Cylinder Block Joint |
US10220453B2 (en) | 2015-10-30 | 2019-03-05 | Ford Motor Company | Milling tool with insert compensation |
US10094328B2 (en) | 2016-07-22 | 2018-10-09 | Ford Global Technologies, Llc | Forming assembly and method to provide a component with a passageway |
JP2018035692A (en) * | 2016-08-29 | 2018-03-08 | トヨタ自動車株式会社 | Cylinder block for internal combustion engine |
CN110082113A (en) * | 2019-04-03 | 2019-08-02 | 陕西渭阳动力技术服务有限责任公司 | A kind of monitoring method remanufacturing diesel engine |
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Also Published As
Publication number | Publication date |
---|---|
US20100000090A1 (en) | 2010-01-07 |
WO2010003067A2 (en) | 2010-01-07 |
CN102084113A (en) | 2011-06-01 |
CN102084113B (en) | 2013-10-23 |
DE112009001596B4 (en) | 2013-03-28 |
DE112009001596T5 (en) | 2011-09-29 |
WO2010003067A3 (en) | 2010-04-15 |
US8191529B2 (en) | 2012-06-05 |
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