5/5/2017 Metrology and Quality

Assurance Lab
Lab Assignment
Submitted to:
Engr. M. Waqas Rafique
Submitted by:
Muhammad Talha Khan
2014-ME-153
 Assignment # 01: Different Machining
Operations for Engine Block and Its Quality
Assurance

Casted Engine Block:

First, a sand mold is prepared from a main metal mold. This sand mold
lasts only for one casting. There is a main core and 17 other cores are attached
to it to make the mold. The molten metal is poured in to the mold through the
smaller front center hole which fills the mold from bottom back up to the top
through the risers, which can be seen as 8 large holes. When the casting is
cooling down the molten metal in the riser is drawn back down in to the casting.
The risers act a main part in the casting process by supplying required molten
metal during shrinkage.

The rough aluminum block casting is shown above after the removal of
the sand mold. the sand is removed by applying vibrating on the casting. The
casting must be machined to get correct dimensions and smooth surfaces of the
engine block.

Figure 1. Casted Engine block

Machining:
Following machining operations are performed on the casted engine block
to achieve the desired dimensions and finishing.
1. Surface Grinding
The surface grinding operation is performed on rough aluminum cylinder
block to get smooth surfaces in the head gasket face and the faces where other
components are fitted.
2. Boring
Then the block is ready for the line boring of the main bearing bores.
Bearing caps are fitted temporally for the line boring of the main bearing bores.
Then in to the line boring of the crank and the cam shaft bearing housings. The
boring bar contains multiple tools so in one operation all the boring operations
are done. Therefore, the boring bar is carefully positioned in the mold. After the
boring, has being finished the crank and cam shafts are fitted temporally to
check the clearances at the bearings. Now the engine block is ready for the
further fittings of crank, cam, cylinders, connecting rods, and valves.

Quality/Dimension Check:

For the dimensional checking we will use the following methods:

1. Vernier calipers

2. Block/shim/J. Block gauges

3. Angle gauges

4. Bevel protector

5. Coordinate measuring machine

6. Solid sphere apparatus

 Rectangular patterns

Large circles

Angular patterns

Figure 2. Engine Block

Figure 3. Top view of Engine Block

 First of all, we will use Vernier calipers to measure the circles diameters
and their thickness which are some much smaller. We can use inside
Vernier calipers to measure the inside diameter of larger circles at the top
 Secondly, we would use block / shim / J. block gauges to measure the
height and width of the square and rectangular shapes made at the sides
of the engine block

 Further, for measuring the angles of the front and side patterns we can
use angle gauges. Basic idea will be to make angle gauges of the standard
angle that was required and checking the angles with its respect

 Then, bevel protector will be used for the measurement of the angles of
the corners to see if they are at the correct angles or not

 Now, we will use the solid sphere apparatus to measure the taper of the
larger holes on the top side of the engine block

 At last, we will use coordinate measuring machine for the measurement

of the top side arcs of the engine block to see if they have a dimension that
was required before