Skimming Cast Iron Cylinder Heads

Sequence of operation:

Before beginning the process of surface grinding a cylinder head, check corrosion or cracks by visual inspection, using a pressure test machine or magnaflux machine.

· Tidy the workstation and check the accuracy of measuring instruments.

· Check warpage with straight edge and filler gauge.

· Measure thickness of head with a vernier caliper and determine if thickness is within manufacturers' specification.

· Remove dwells or any protruding attachments that are above the surface plane .

· Clean the base of the workpiece on the part that seats on the parallels.

· Secure the cylinder head on the parallels and machine bed with the surface to be ground level to the reciprocating axis of the surface grinder using a spirit level or DTI.

· Dress and true the segmented grinding wheel.

· Grind the surface until it is level and at the desired finish (Use sufficient soluble oil).

· Remove cylinder head from machine and clean head.

· Apply rust inhibitor to machined surface.

The End

Cylinder Block Rebore

Sequence of Operation:

· Tidy the workstation and check the accuracy of measuring instruments.

· Check the cylinder bore size with an inside micrometer.

· Determine the size to be bored to and check the availability of pistons and rings.

· Clean the base of the block and then secure the cylinder block on the machine bed.

· Mount the correct boring spindle and boring head on the rebore machine.

· Fit a radial finger to the machine spindle head and clock a cylinder bore true under the ridge. Lock the machine bed in position and remove the radial finger after clocking.

· Grind a cutting tool to the correct angle and radius.

· Secure the tool in the spindle head at the correct height using a direct reading micrometer.

· Select the correct speed and feed and bore down a trial cut approximately 6mm long.

· Check the size with an inside micrometer and adjust the tool if necessary.

· Bore through the cylinder bores.

· Cut a chamfer at the top of the cylinder at 45degrees.

· Remove the block from rebore machine and hone.

· Wash honing oil off and apply rust inhibitor on machined surface.

The End.

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My Mission

My mission is to boldly go where no other machinist has been before.

Seriously! This is what I intend to do. This is the first of series of articles where I will be talking mainly about automotive precision machining. I will try to share with you from my 9 years experience (4yrs appy & 5 yrs post appy).

I am hoping that this will be a launch pad to establish some concise forum for the machining aspect of automotive engineering.

One thing that has always been eating me is that, to the best of my knowledge, there are no specific books for Automotive Precision Machining. During my years of training we tied General Machine Shop Technology books with Motor Vehicle Technology books to get a theoretical understanding. The gaps where filled in by notes from the lecturer and plenty research.

I plan on coming up with one book that covers all these basics in this specialised field.

I will probably also drag you through a few sequences of operation in the hope of teaching you what I know but mainly so that I may learn from you through your comments.

WELCOME.

Welcome to my blog!

This is the first of a series of posting where i will be talking mainly about the machining aspect of automotive engineering. I trust that you will enjoy exploring the exciting world of precision engineering as much as i enjoy writing the articles.