MTM LAB ASSIGNMENT

Enlist the machining operations seen in the diagram below in a sequence and Design
a fixture to clamp the engine casting. Make sure you must design the fixture in such
a way that the degree of freedom of engine should be Zero. (10)

Raw casting

Top and side view bottom view

 Machining operations involve in the Engine Block
Manufacturing
1) Milling (for flattening reference surface):
Initially when we have a raw casting then no side of the raw casting is
perfectly smooth (plan) due to errors in the casting process. In that situation if
we hastily start the process by choosing any side to be machined first then we
will encounter a number of problems and finally the surface achieved and all
features referenced from that surface will not be perfect because the bottom
surface of the raw casting block was not flat and here comes a big problem.
1) To flat the surface of the block that will be placed upside down first to
machine other sides of the work, we need rectangular blocks of
different sizes and packing pieces of the greater strength and thickness
all for the purpose of getting nearly flat surface at the top. The rest will
be done by the milling process.
2) To grab the block securely we will use a table with T-slots and since our
main focus is on flattening the top surface and getting corners that are
right to each other, we can grab the work from sides to any height
because we are not going to perform any process on those sides.
3) So, our fixture will be simple but we have to exert an effort for getting
nearly flat surface on the top by placing different blocks and packing
pieces.
4) In this step we will perform only milling and will make edges right to
each other form top. This surface will become reference surface and
will be placed upside down in the next step.
5) Now the bolts of the T slots will be loosened and supporting blocks will
be moved away from the work to free the grabbed sides of the work.
6) Depending upon the weight of the block a crane is used to lift the block
and arrangements fixture are brought, seated, fixed and then the
machined surface is seated on the parts 1 and 2 such that it faces the
surface of the table. Now, the rough surface is at the top for machining
operations.
7) Two sets of grabbing devices are positioned to grab the block tightly
and securely all of which are controlled independently.
8) Now milling is performed on this surface to flat it. For that purpose, any
milling tool depending on the material of the block to be machined is
 chosen and efforts are made to not remove much of the material to
avoid wastage.

2) Drilling:
Drilling may be defined as the operation of producing a hole by removing
metal from a solid mass using a cutting tool called a twist drill.
Although many circular and cylindrical features are made in the casting
but some additional are drilled in the block for the purpose of cooling, attaching
accessories for holding, lifting or for those holes that are too small and its better
to drill them.
Standard tools and machines are used depending upon the nature of our
job. Usually holes to be drilled are not too larger and do not impose any problem
in machining. Usually HSS or carbide tool bits are used because they are efficient.
All holes positions are referenced from one edge of the work piece. Now this is
the advantage of flattening the surface and making all edge at right angle to each
other.

3) Boring:
Boring is defined as enlargement of a hole diameter which is already
drilled. Drilling may be defined as the operation of producing a hole by removing
metal from a solid mass using a cutting tool called a twist drill.
Boring is often essential in the machining of casted block because the
machined circular feature is not true and are often kept smaller in size in order
to machine them later to exact size. So, first of all a boring tool which is a long
rod at the end of which is mounted a single point cutting tool that will operate in
a manner to perform a kind of internal turning is fixed at the center of the hole.
Top flat surface will help us get this point. Then boring is performed to enlarge

the hole. At the end it is ensured that the hole is straight and we have achieved the required
size of the hole.
 4) Counter boring:
Counter boring is the operation of enlarging the top of a previously drilled
hole to a given depth to provide a square shoulder for the head of a bolt or caps
crew.
After boring a previously drilled hole we will go for counter boring, in which
the hole diameter is further enlarged but to a specific depth to provide seating
to the head of a bolt. Its purpose is to eliminate all protruding edges.
5) Reaming:
If the resulting hole is not true and we require smoother hole then the one
machined, we will perform a reaming operation. Reaming is the operation of
sizing and producing a smooth, round hole from a previously drilled or bored hole
with the use of a cutting tool having several cutting edges.
All these three operations of drilling, boring and reaming can be
performed on the same machine without sliding the fixture assembly. Although
boring gives us a better finish then the drilling but more fine surface finish can be
obtained in a reaming operation and also it lasts longer as all cutting edges cut
throughout the length uniformly.
6) Threading/Tapping:
Tapping is the operation of cutting internal threads in a hole with a cutting
tool called a tap. Special machine or gun taps are used with a tapping attachment
when this operation is performed by power in a machine.
Tapping tools are simple there are threads on the external side of the tool.
This tool is inserted inside the drilled or bored hole and are rotated/turned to
produce internal threading in the holes. Small countersinking ease the start of
the tapping process. Once the holes are trued by the reaming operation there
will be no difficulty in finding the center of the hole and performing other
operations like tapping.

7) Surface grinding:
Although milling provides us with a plan surface, we still need to achieve
the required surface finish. For this purpose, surface of all machined sides are
surface grinded.
In the grinding process, the work piece is brought into contact with a
revolving grinding wheel. Each small abrasive grain on the periphery of the
wheel acts as an individual cutting tool and removes a chip of metal
. As the abrasive grains become dull, the pressure and heat created
between the wheel and the work piece cause the dull face to break away,
leaving new, sharp cutting edges.
 As in our case we require a surface finish of 0.5 m for all surfaces so we
will perform a surface grinding operation to achieve this surface finish.
8) Honing:
The basic honing process removes the rough machine marks left by boring
bar, smoothing the cylinder wall while still leaving a sufficient cross-hatch pattern
in the cylinder wall to help lubricating rings. Even after honing, if magnified, the
cylinder wall will look like a landscape of peak valleys. Its the valley that retain
the oil. Overall this process is performed at the end to provide extra shine and
smoothness to the cylindrical bores.
Fixture Deigned for Holding Engine Block
Fixture Specifications:
Fixture Bed Length = 28in
Fixture Bed Width = 19.5in
Fixture Material = Alloy Steel
Parts:
1) Base Frame
2) Holding Plates
3) Fixing Nuts
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