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Unit 8
Title: Cylinder Cylinder Head General objective:
To understand the application and structure of the cylinder block and head.

Block

and

Specific objectives:
At the end of this unit you should be able to: 1. 2. 3. explain the application of the cylinder block. explain the material selected to provide cylinder block. explain two types of sleeve 3.1 Wet sleeve 3.2 Dry sleeve 4. 5. explain the advantages and disadvantages of sleeve. discuss the design of a cylinder head.

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6.

discuss a cylinder head type CVCC and TGP.

Input
This section introduces the subject matter that you are going to learn.
8.0 Introduction A cylinder block and cylinder head are the main supporting structures to which all other engine parts are attached to. This unit is about the cylinder block and cylinder head of an engine. 8.1 Cylinder Block The cylinder block is the main component of an engine. It houses, supports, and positions other parts for precise operation. Engineers have developed many types of cylinder blocks, such as the L- head (side valve), V twin, and twinopposed types, to fit equipment requirements. Small, single-cylinder, air-cooled engine blocks are generally cast in two pieces, the removable end-wall section (the oil sump on vertical models) and the main block. The block is made up of the crankcase and the cylinder. The end wall (sump) and block are pin-aligned and bolted together. Precise machining is accomplished for camshaft and crankshaft bearings. The blocks of the engines are generally made of aluminium but may have a steel cylinder liner (sleeve). Cast-iron engines fill the need for heavy-duty commercial works. Figure 8.1 shown a cylinder block four cylinder engine. Cylinder blocks can be categorized into two categories: replaceable cylinder

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liners and fixed cylinder liners. Engines with replaceable cylinder liners are usually called sleeved engines

Figure 8.1 : Cylinder Block Construction 8.2 Cylinder Block Material Selection A cylinder block is made by casting process due to its complex feature. Once the cylinder block is cast , and after it has been cooled and cured, surfaces are machined so other parts can be attached to the block. These surfaces include the cylinders, top of block (deck),camshaft bore, crankshaft bore, and oil pan surfaces. The front and rear of the block mounts are also machined so that the parts can be attached and sealed correctly. Materials that are used to make a cylinder block are: i) Cast Iron/steel i) Aluminum ( for smaller engine) 8.3 Differences between Aluminum and Cast Iron In theory, cylinder block which contains iron heads do not conduct as much heat away from the cylinder as aluminum does, so the iron heads should be made more powerful. With the increased concern for improving gasoline mileage, however, car manufactures are trying to make the vehicle lighter. Besides that, aluminum weighs less and is generally much easier to

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repair. One way to reduce the weight in the block, aluminum is used for this purpose. Iron is less expensive but weighs more. Silicon is also added to the aluminum. Through a special process, the silicon is concentrated on the cylinder walls. This design is called silicon-impregnated cylinder wall. 8.4 Cylinder Sleeves Some manufacturers use cylinder sleeves. Rather than casting the cylinder bores directly into the block, they insert a machined sleeve (Figure 8.2). Sleeves are inserted after the block has been machined. The purpose of using a sleeve is that, if the cylinder is damaged, the sleeve can be removed and replaced rather easily. Blocks which already have sleeves have to be bored out to remove any damage. After boring, larger piston will be needed. There are two types of sleeves; a wet sleeves and a dry sleeve. The dry sleeve is pressed into a hole in the block. It can be machined quite thinly because the sleeve is supported from the top to the bottom by the cast iron block. The wet sleeve is also pressed into the block. The cooling water touches the center part of the sleeve. This is why it is called wet sleeve. Seal must be used on the top and at the bottom of the wet sleeve. Seals are used to keep the cooling water from leaking out of the cooling system. Wet sleeves are used on some larger diesel engines. Advantages of a sleeved engine: i) ii) easily reconditioned in frame engine manufacturers are able to produce cylinder liners from special wear-resistant and heat-treated alloys

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Figure 8. 2: Types Of Cylinder Sleeves

Activity 8A
This section tests your understanding of the subject matter. You are to answer the following questions.
8.1 List down two types of cylinder blocks in single-cylinder air-cooled engine blocks that are cast. i. _____________________________________________________________ ii. ____________________________________________________________ 8.2 What are the materials used to make cylinder block? _______________________________________________________________ _______________________________________________________________ 8.3 Name two categories of a cylinder block i. ____________________________________________________________ ii. ____________________________________________________________ 8.4 List two types of Cylinder Sleeve: i. _______________________

ii. _______________________

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8.4

Cylinder Head The cylinder head closes one end of the cylinder and encloses the combustion chamber, which is cast into cylinder head. The cylinder head includes the valve guides, valve seats, ports, combustion chamber, water jackets, threaded holes for spark plug, other threaded hole for attaching parts, and several machined surfaces. The size of the chamber and stroke of the piston determine the compression ratio of the engine. The spark plug is threaded into the cylinder head with the spark plug electrodes protruding into the combustion chamber for each cylinder or piston. This establishes the point where ignition takes place. The cylinder head also has fins to release the heat of combustion into passing air flow. Figure 8. 3 shows the structure of the cylinder heads.
Toyota 1985-1995 22R Cylinder Heads...

Special purchase of brand new cylinder heads, for Toyota 22R engines... Cylinder heads are complete with; valves, valve springs, retainers and keepers.

Larger Image

The 2.4 liter 4-cylinder 22R engine came in certain year Toyota Celicas, 4Runners and Pickup trucks.

Larger Image

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Figure 8.3: Structure Of Cylinder Head 8.5 Cylinder Head Materials Cylinder head can be made from cast iron or aluminum. Aluminum is used to make the engine lighter, but it transfers heat more rapidly and expands more than cast iron with the addition of heat. The cylinder head must have an intake and exhaust port. After the cylinder head has been cast, it must be machined. Areas must be machined so that intake and exhaust manifolds can be attached, valves can be seated, sparks plugs and injectors can be installed, and a good seal can be provided to the block. Intake and exhaust ports must be cast into the cylinder head. These ports are made so the air and fuel can pass through the cylinder head into the combustion chamber. Figure 8.4 shows the parts of the cylinder head.

Figure 8.4: Cylinder Head Construction 8.6 Combustion Chamber The shape of the Combustion Chamber affects the operating efficiency of the engine. Two types of combustion chamber designs are commonly used and they are the Wedge- Shaped Combustion Chamber and The Hemispherical Combustion Chamber.

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The WedgeShape Combustion Chamber was used on cast until about 1968. Refer to Figure 8.5. As the piston comes up on the compression stroke, the air and fuel mixture are squashed in the quench area. The quench area causes the air and fuel to be mixed thoroughly before combustion chamber. This helps to improve the combustion efficiency of the engine. Spark plugs are positioned to get the greatest advantage for combustion. When the spark occurs, smooth and rapid burning moves from the spark plug outward. The Wedge Shaped Combustion Chamber is also called a Turbulence-Type Combustion Chamber.

Figure 8. 5: Wedge Shaped Combustion Chamber The Hemispherical Combustion Chamber is also called the Hemi-Head. The valves are located as shown in Figure 8.6. The Hemispherical Combustion Chamber is considered a No turbulence-Type Combustion Chamber. The air and fuel mixture is compressed evenly on the compression stroke. The spark plug is located directly in the center of valve. The advantages of the Hemispherical Combustion Chamber are that air and fuel can enter the chamber very easily.

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Figure 8.6 : Hemispherical Combustion Chamber The Swirl Chamber is designed to provide better mixing of the air and fuel particles to improve combustion. This results in better fuel economy and lower exhaust emissions since fewer unburned hydrocarbons enter the exhaust system. The swirl effect is achieved by intake port design, port location in the combustion chamber, and the shapes of the chamber itself. This design factor results in a corkscrew type of flow of the air-fuel mixture in the cylinder as the piston move up and down on the intake stroke. As the piston come up on the compression stroke this agitation of the air-fuel mixture continues and is compounded by compression ( Figure 8. 7).

CYLINDER BLOCK AND CYLINDER HEAD 8/ Figure 8. 7: Swirl Chamber

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The MCA (Mitsubishi Clean Air)

Combustion Chamber

uses three

valves : intake, exhaust and A jet valve. The jet valve is also an intake valve. Air from the carburetor throttle plate is directed to the jet valve at lower engine speed. This results in a swirling action in the chamber and increase turbulence (Figure 8.8 ).

Figure : 8.8: MCA Combustion Chamber The Honda CVCC (Controlled Vortex Combustion Chamber) is a stratified charge chamber ( Air-fuel mixture is layers or strata). It has two chambers the main combustion chamber and auxiliary chamber- and three valves the regular intake and exhaust valve and a smaller auxiliary intake valve that opens into the auxiliary chamber ( Figure 8.9). The small valve admits a rich air fuel mixture into the auxiliary chamber, while a leaner mixture is admitted past the intake valve into the main chamber. This results in an overlap of the rich and lean mixture near these openings. In operation, the spark plug ignites the rich mixture in the auxiliary chamber, causing rapid flame propagation through the rich mixture first, then

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through the overlap mixture, and finally through the lean mixture in the main chamber. This results in good combustion and reduces exhaust emission.

The multivalve design is used in across-flow arrangement with intake valve on one side and exhaust valve on the other side (Figure 8.9). There are two camshafts, one for intake valves and one for exhaust valves. This result in more complex camshaft mounting and camshaft drive requirements. The advantages of the multivalve chamber include greater volumetric efficiency resulting from the increased flow rate, central spark plug location for better combustion, reduced emissions, better performance, and increase fuel economy.

Figure 8.9: CVCC (Controlled Vortex Combustion Chamber)

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Activity 8B
This section tests your understanding of the subject matter. You are to answer the following questions.
8.5 What is the main function of a cylinder head at the engine? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________ 8.6 Based on the figure below, label the parts of CVCC Combustion Chamber

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8.7

List down three types of Combustion Chamber found in Internal combustion engine. i.________________________________________ ii. _______________________________________ iii._______________________________________

8.8

List the steps in the process of manufacturing cylinder head. i. ii. iii. iv. a. b. c. d. Casting Line boring Machining Honing i and iii i and ii ii and iv i,ii, iii and iv

8.9

Explain the purpose of Combustion Chamber in the internal engine. _______________________________________________________________ _______________________________________________________________ _______________________________________________________________

8.10

What are the materials needed to make a cylinder head?

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_______________________________________________________________ _______________________________________________________________

Self Assessment
Self-assessment evaluates your understanding of each unit.
Question 9.0 List the different types of engine blocks produced Question 9.1 Explain the differences between aluminium and iron particularly in making cylinder block Question 9.2 Name two types of sleeves and the advantages of sleeves Question 9.3 Why most engines use the sleeve cylinder at the engine block

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Question 9.4 Describe the operation of a Controlled Vortex Combustion chamber (CVCC ) Question 9.5 Explain the advantages when an engine uses a multivalve design at the combustion chamber.