Design and manufacture of a single cylinder block for a 150cc engine with an Al 7075 alloy

Abstract

Introduction: Computer aided manufacturing (CAM) and aluminum casting processes play a fundamental role in the development of automotive parts and pieces with a high degree of precision, reducing costs and time. Objective: Manufacture a 150 cc single-cylinder engine block, using 7075 aluminums as raw material, from a "biscuit" type casting process obtained in CAD software, then printed on a 3D printer until obtaining the male molds in silica sand combined with sodium silicate as a hardening and forming binder. Methodology: Literature review of aluminum alloy casting processes, reverse engineering, 3D printing, casting process by the "cookie" method. Results: Liquid aluminum was poured into the mold at an average temperature of 850°C combined with zinc (5.1-6.1%), magnesium (2.1-2.9%), copper (1.2-2%), and silicon, iron, manganese, chrome, and titanium in small proportions. Once the prototype had cooled, it was demolded and machined on a 4-axis machining center and finally the pressure jacket was inserted until the finished block was obtained. Conclusions: A single cylinder 100 cc engine block prototype was obtained. fully functional. General study area: Engineering. Specific study area: Casting processes.