Miniaturized Cylinder Head Production by Rapid Prototyping

Proceedings of COBEM 2009 Copyright © 2009 by ABCM

20th International Congress of Mechanical Engineering November 15-20, 2009, Gramado, RS, Brazil

MINIATURISED CYLINDER HEAD PRODUCTION BY RAPID PROTOTYPING
MELO, Rodrigo N., [e-mail]
Universidade do Minho, Campus de Azurem, 4800-085 Guimarães, Portugal.

MONTEIRO, António A.C., [e-mail] Universidade do Minho, Campus de Azurem, 4800-085 Guimarães, Portugal MARTINS, Jorge J.G., [e-mail]
Universidade do Minho, Campus de Azurem, 4800-085 Guimarães, Portugal.

COENE, Stijn, [e-mail]
Universidade do Minho, Campus de Azurem, 4800-085 Guimarães, Portugal.

PUGA, Helder F., [e-mail]
Universidade do Minho, Campus de Azurem, 4800-085 Guimarães, Portugal.

BARBOSA, José J.C., [e-mail]
Universidade do Minho, Campus de Azurem, 4800-085 Guimarães, Portugal.

Abstract. This work shows the development of the design and manufacturing of a very small engine, namely its head. The engine works under the 4-stroke cycle, therefore having a very complex cylinder head, housing the camshaft, valves and its auxiliaries (seats, guides, springs), spark plug, inlet and exhaust passages and a coolant chamber. The geometries, both inner and outer are highly intricate which makes the production of such a part a very difficult job. In addition, when the engine is very small, as it is the case of this engine, all dimensions are miniaturized therefore making it extremely difficult to design, cast and finish. The cooling chamber, in particular, has a critical inner core removal problem due to reduced accessibility, imposing casting limitations. The cores place also a problem of air and gas removal during metal filling and solidification. Rapid prototyping may be the only solution to build the cores, and may help in the design and manufacturing phases of the casting tools. 3D printing with a plaster based material as a rapid prototyping technique presents

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