Fundamentals of Engine Block

Design

Harold Garing

GROUP 3 PART 1

September 2018
Lessons

Design Concept And Structure

Material Selection
Cylinder Head Design Parameters
Design Concept And Structure

Engine Block

Engine block which is also called as

cylinder block is the main structure of
the engine which give the space for
the cylinders and the main housing of
multiple parts and surrounding
structure found in modern engines.
Design Concept And Structure

History

The first commercially successful internal

combustion engine was created by Étienne Lenoir around
1859 and the first modern internal combustion engine
was created in 1876 by Nikolaus Otto (see Otto engine).

Early engines, particularly those with more than four

cylinders, had their cylinders cast as pairs or triplets of
cylinders, then bolted to a single crankcase.
Design Concept And Structure

Designing and Manufacturing

Engine Block must be design for the

requirements include the wear
resistance, long lasting, maintenance,
and withstand the pressure created
when combustion take place. It also has
to withstand high temperature, vibration
when the engine is in the running
conditions
Design Concept And Structure

Designing and Manufacturing

engine blocks are mainly done using

sand casting, although die casting also
used it is more cost effective as the die
wear out easily due to the high
temperature of the molten metal.
Design Concept And Structure

Engine Block Structure

Material Selection

Factor Consideration
Factors
High Strength
Modulus of Elasticity
Wear Resistance
Vibration Durability
Corrosion Resistance
Low Density
Low thermal expansion / High Thermal Conductivity
Machinability and Castability
Availability
Material Selection

Types of Material

Based on the factors consideration of the cylinder block and

the material properties required to meet the functional
requirements, industries have used cast iron and aluminum
alloys to manufacture the blocks.

• Grey Cast Iron

• Compacted Graphite Cast Iron
• Aluminum Alloys
Material Selection

Grey Cast Iron

• The first and most material used for manufacturing of engine

blocks.

• It has a excellent damping absorption, good wear and thermal

resistance, and it is easily machinable and less cost due to its
availability.

• Good for diesel engine

Material Selection

Compacted Graphite Cast Iron

• It has a higher tensile strength and modulus of elasticity

compared with grey cast iron.

• Similar to grey cast iron it has a good damping

absorption and thermal conduction, but its low
machinability has limited its wide usage.
Material Selection

Aluminum Alloys

• main feature for its popularity is its low weight, this

reduce the weight of the engine as well as in the vehicle.

• Aluminum alloy has a good machinability properties

compared with grey cast iron.

• main disadvantage is their cost compared with grey cast

iron.
Cylinder Head Design
parameters

Cylinder Head

It sits above the cylinders on top

of the cylinder block.

It also place to mount

the valves, spark plugs, and fuel
injectors.
Cylinder Head Design
parameters

Design Parameters

Main Parameters
Airflow Number
Valve Angles
Engine Fuel Type
Head type
Guidance from Supplier
Cylinder Head Design
parameters

Air Flow Number

the design of cylinder head for

maximum optimization airflow for
combustion
Cylinder Head Design
parameters

Valve Angle

Requires for head to design

the angle of valve for airflow
optimization.
Cylinder Head Design
parameters

Fuel Type

Diesel and Gasoline are the

two main fuels use in an
internal combustion engine
used in automotive
Cylinder Head Design
parameters

Head Type
Cylinder Head Design
parameters

Cylinder Head Structure

THANK YOU !!!