Design of a OverHeadCam Cylinder Head For a Small IC Engine

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Design of a Over-Head-Cam Cylinder HeadFor a
Small IC Engine

• Brett Durie Senior Project 2003-2004
• Advisor Prof. Brad Bruno

Casting Background
Aluminum casting is a widely used process for
the manufacturing of engine parts including
engine blocks and cylinder heads. The two
techniques employed most often for this process
are sand casting and lost foam casting.
Sand casting requires a pattern made of wood or
steel that is packed in sand and then removed to
leave a void in which molten metal is poured.
This process is very useful for mass production
because once the pattern is made, the molds are
easily reproduced. Complicated parts with lots
of curves and passageways are made using a lot of
cores. Cores are molded shapes of sand that are
set into the mold to take up space so that thin
walls and passages can be cast. This method is
not suitable for only a few parts because the
initial pattern and core system is very difficult
to make. The first step in the lost foam
casting process is to make a foam pattern to
almost the exact dimensions of the desired final
product. The pattern is buried in sand and then
the molten metal is poured in. The foam
instantly evaporates and is displaced by the
metal. The process is especially useful for
complex parts because the pattern does not need
to be designed for removal from the mold.
Base Motor