The cylinder

The cylinder must maintain an accurate roundness and straightness of the
order of μm during operation. The cylinder bore wall typically  experiences local wear at the top-dead-center point, where the oil film is most likely to fail, and scratching along the direction of travel of the piston. Figure 2.5 shows vertical scratching caused by scuffing. The grooves caused by scratching increase oil consumption and blow-by. In extreme cases, the piston seizes to the bore wall. The demand for higher output with improved exhaust gas emission has recently increased heat load to the cylinder even more. A much lighter weight design is also required.An engine generating high power output requires more cooling, since it generates more heat. Automotive engines have two types of cooling systems, air-cooled and water-cooled. Figure 2.1 shows the air-cooled type and Fig.2.2 the water-cooled type. Whilst an air-cooled engine may use a much simpler structure because it does not use the water-cooled system, the heat management of the cylinder block is not as easy. As a result, most automotive engines nowadays use water-cooled systems. It would be no exaggeration to say that the required cooling level for an individual engine determines its cylinder structure.
Figure 2.6 shows cutaway views of four different types of cylinder block structure. The monolithic or quasi-monolithic block (on the right) is made of
only one material. It is also called a linerless block because it does not contain liners (described later). The bore wall consists of either the same material as the block or a modified surface such as plating to improve wear resistance. It is normally difficult for one material to fulfill the various needs listed in Fig. 2.4. However a liner-less design in multi-bore engines can make the engine more compact by decreasing inter-bore spacing.
The other designs in Fig. 2.6 (on the left) incorporate separate liners. A liner is also called a sleeve. A wet liner is directly exposed to coolant at the outer surface so that heat directly dissipates into the coolant. To withstand combustion pressure and heat without the added support of the cylinder block, it must be made thicker than a dry liner. A wet liner normally has a flange at the top. When the cylinder head is installed, the clamping action pushes the liner into position. The cylinder head gasket keeps the top of the liner from leaking. A rubber or copper O-ring is used at the bottom, and sometimes at the top, of a wet liner to prevent coolant from leaking into the crankcase. A dry liner presses or shrinks into a cylinder that has already been bored. Compared to the wet liner, this liner is relatively thin and is not exposed to the coolant. The cast-in liner design encloses the liner during the casting process of an entire cylinder block.
Table 2.1 lists various types of cylinder structures, their processing and characteristics. Cylinder blocks are normally made of cast iron or aluminum alloy. The aluminum block is much lighter. Various types of materials are combined to increase strength. In the following sections, we will look at the blocks of four-stroke engines. Those for two-stroke engines are discussed in the final section.



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  • The science and technology of materials in automotive engines
    Hiroshi Yamagata
    Woodhead Publishing and Maney Publishing
    on behalf of
    The Institute of Materials, Minerals & Mining
    CRC Press
    Boca Raton Boston New York Washington, DC
    WOODHEAD PUBLISHING LIMITED
    Cambridge England



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  • 6:20:00 AM

    Car Magnets - an effective advertising medium

    A great way to advertise your business or organisation is to use the vehicles. They represent a really great medium for advertising and promotion as they are visible, mobile and cost effective.

    You have several options: First of all, there is the more permanent method of painting on the vehicles or you can also have the really popular method - using customized vinyl decals which can partially or fully wrap the vehicle. Another method which is fast gaining in popularity is the use of magnetic signs. These offer several advantages over the previous two methods namely, in terms of flexibility and relatively inexpensive as well. They can be removed easily and transferred to other positions or vehicles.

    Sometimes if you are using your car for both commercial and private purposes, you may not want the sign on all the time. In this case, magnetic signs are the obvious choice. On the other hand, these signs have certain limitations in the sense that it may not be possible to have full coverage or have them go round the curves or the vehicle.

    Anyway, I was going through the CarMagnets.com - a company which specialises in car magnets.

    According to the company, their signs use high quality material, with non-fading ink which is UV and scratch resistant. However, I guess there is a small mistake on the home page at the top as it says that you can choose from 3 sizes when in fact, they offer five standard sizes of magnetic car signs.

    They take away the difficult job of designing your own signs by offering over 100 templates to choose from. To make it easier, the templates are also grouped under different categories ranging from "Just Married" to "Autism Awareness" - all you have to do is add your own slogan or company name. On other other hand, if you are the artistic type or know someone good with graphics - you also have the option of uploading you own graphics and then use their online editing tool to add additional text.

    I feel that a little bit more information about the advantages of magnetic car signs and also some more information about the company would help. It also appears that their pricing page is still under construction - not a great way to instil confidence in prospective customers. They could also do with a more professional looking logo. Apart from that, I think the site is really innovative and their online editing tool is really user friendly as well. It took me less than 5 minutes to choose a template and create my own sign.

    Check out the site in case you are thinking of getting a magnetic sign for your car.

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