Method Of Manufacturing An Engine Block

Abstract

A method for manufacturing an engine block, such as for an internal combustion engine, includes a step of removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area. Material is also removed from the top deck of the engine block surrounding at least one fluid passage to create a second removal area. An insert is positioned within a recessed area defined by the first removal area and the second removal area.

1 . A method for manufacturing an engine block, comprising:
 removing material from a top deck of the engine block surrounding a cylinder bore to create a first removal area;   removing material from the top deck of the engine block surrounding at least one fluid passage to create a second removal area; and   positioning an insert within a recessed area defined by the first removal area and the second removal area.   
     
     
         2 . The method of  claim 1 , wherein the second removing step includes removing material from the top deck of the engine block surrounding each of a plurality of fluid passages circumferentially spaced about the cylinder bore. 
     
     
         3 . The method of  claim 1 , wherein at least one of the first removing step and the second removing step includes machining out a crack within the engine block. 
     
     
         4 . The method of  claim 3 , wherein at least one of the first removing step and the second removing step further includes machining out the crack radiating from the cylinder bore. 
     
     
         5 . The method of  claim 3 , wherein at least one of the first removing step and the second removing step further includes machining out the crack radiating from the at least one fluid passage. 
     
     
         6 . The method of  claim 1 , wherein the positioning step includes press fitting the insert within the recessed area. 
     
     
         7 . The method of  claim 6 , wherein the positioning step further includes aligning a keyed feature of the insert with a complementary keyed feature of the recessed area prior to the press fitting step. 
     
     
         8 . The method of  claim 6 , further including machining the insert to a thickness greater than a depth of the recessed area. 
     
     
         9 . The method of  claim 8 , further including planing the top deck of the engine block after the press fitting step. 
     
     
         10 . The method of  claim 1 , wherein the first removing step and the second removing step include removing the material using a computer numerical control machining tool.