Engine Block Machining Process Explained
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ScribdTranslationsEngine Block Machining Process Explained
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ScribdTranslationsENGINE BLOCK RECTIFIED
The grinding operations on the engine block are carried out on the cylinders and on the flatness of the face.
of the block that connects to the cylinder head. The blocks that allow for grinding are the integral blocks, and the
The main cause of rectification is the wear produced by the friction of the segments on the
cylinder wall. This friction produces a conicity inside the cylinder and an ovality of the
inner diameter. When the conicity or ovality of the cylinder due to wear exceeds 0.15 mm (or
the measurement indicated by the manufacturer), it is advisable to recondition the engine cylinders.
Another cause of honing or polishing the inside of the cylinder is the seizure of the piston with the cylinder, since
the wall of the cylinder can be damaged and in such case it would be necessary to grind.
In the process of rectification of the
engine block must be taken into account:
Measure the wear, taper, and ovality of the block with an alexometer or vernier.
Verify that the manufacturer allows grinding and that it provides the dimensions and parts for a possible
Rectification
The manufacturer can allow up to four corrections at 0.2 mm each correction as well as sets of
pistons and oversized rings to the new machining measurements. Generally, manufacturers
They have oversized pistons by 0.1, 0.2, 0.4, and 0.8 mm, compared to the original or standard diameter.
The following table shows an example of correspondence between pistons and cylinders.
About measures Diameter Diameter Game of
Piston Cylinder assembly
St
74.95 75 0.05 ± 0.01
0.1 75.05 75.1 0.05 ± 0.01
0.2
75.15 75.02 0.05 ± 0.01
0.4
75.35 75.04 0.05 ± 0.01
0.8
75.75 75.8 0.05 ± 0.01
As can be seen, the nominal or standard size of the cylinder is 75 mm in this case, to which
it corresponds to a piston of 74.95 mm, with a mounting clearance between the two of 0.05 mm. From
a grinding over 0.8 mm, there are no pistons in stock. This is logical, as the increase in the
displacement that involves an oversize greater than 0.8 mm would cause an intolerable thinning of the
cylinder walls that could not withstand the explosions of the engine during its operation, there is also
Keep in mind that we are increasing the engine displacement and therefore the compression ratio of the
engine, so we may have the problem of autoignition (rod knock).
It is understood that the grinding operation must be performed on all cylinders at the same time.
customized, regardless of its wear, thus maintaining the same displacement in all of them, and in
consequence, equal power. Otherwise, the power imbalances between the different
cylinders would lead to irregularities in the engine's rotation and dangerous imbalances, which could
to cause the breakage of some component.
When the grinding operation consists of removing a very thin layer of material due to having little
wear the cylinder, it is enough to perform a grinding operation. This operation is carried out with a
machine that has a rotating shaft equipped with a head with strips of abrasive material that is inserted
in the perfectly centered cylinder with it. During the grinding operation, the head rotates at the same
time that moves up and down. The abrasive material, extensible at will to adapt to the
The diameter of the cylinder causes the material to be removed in a grinding action. Subsequently
the head is replaced with another of much finer grain to polish the ground surface.
When the material to be removed exceeds a thickness of 0.15 mm in diameter, the operation proceeds to
rectification, which is performed in machines similar to the one described, in which the abrasive material of
the head is replaced by blades. Normally in grinding, 0.04 mm of material is left, to
to be able to then perform the grinding operation and thus give a fine finish to the walls of the cylinder.
When the wear of a cylinder is such that there is no possibility of grinding, it must be proceeded to
lining, which consists of mounting new sleeves on the cylinder. This returns the engine to its
original displacement. The new sleeves are mounted in the cylinder in special presses, with
The cylinder must be rectified to a diameter of 0.05 mm smaller than the exterior of the new one.
shirt, in order for it to enter with interference in the cylinder and remain trapped there. After
After the sleeving is done, it is necessary to grind or polish the cylinders to the required measure.
suitable. This eliminates any possible deformations that may have occurred in the
assembly operation.
Engines equipped with wet sleeves will not be rectified. In this case, when the wear...
surpasses
Engine reconditioning according to the tolerances specified by the manufacturer, the replacement of the
shirt-piston sets. In the assembly of these shirts, it should be taken into account that they must protrude from the
plan of the block a certain measure, so that the cylinder head exerts a certain pressure on them, that
Ensure the tightness of the assembly in the block.