Method for manufacturing engine block having recessed cylinder bore liners

摘要

A method for manufacturing an engine block by sand mold casting techniques wherein the cylinder bore liners are recessed from the cylinder head contact surface of the engine block is provided. The outer surface of each cylinder bore liner has at least one circumferential groove formed therein. The cylinder liners are initially positioned in a barrel core box and a barrel slab core is formed by blowing resin coated sand into the core cavity of the barrel core box. Each liner is positioned in the barrel core box such that the groove remains free of sand during the core making process. The barrel slab core is then combined with other conventional core assemblies to form a cylinder block mold. The cylinder block mold is filled with a light alloy metal to produce an engine block casting with caste-in-place cylinder bore liners. The top end of the cylinder bore liners may be cast above or flush with the cylinder head contact surface of the engine block casting. The cylinder bore liners and the cylinder head contact surface are subsequently machined to produce an engine block wherein at least one cylinder bore liner is recessed from the cylinder head contact surface. The machining operations may include milling the top end of the cylinder bore liners and rough boring the inner surfaces of the cylinder bore liners.