Study on Design and Manufacturing of an Engine Block Using Digital Tools

The chapter presents the using mode of some digital tools in the process of design and manufacturing of an engine block used from lightweight four-stroke engine system for competition kart. The combustion engine from automotive industry has the enlarged future because in the green world is grooving the combustion solution with Liquefied Natural Gas (LNG) and, in the last time, Hydrogen. Different digital environments, including CATIAT, provide a large number of tools for design in order to obtain the best constructive solution for a product and later to manufacture it. The design for disassembling is implemented starting with the concept level of the engine block. For the collision check is used the CATIAT DMU Space analysis applied on the 3D engine block model. All parts for engine assembly are moved in functional position using the digital tool from Assembly Design module. Another possible issue, the wrong access for assembly tools is validated using the 3D models for the tools safety spaces. To check the most important designed parts in real world are generated the 3D files and are manufactured the real parts using two additive manufacturing systems. The G code for multi-axis machining of the engine block is generated from CATIAT Machining module and the CNC files are also simulated to be validated in virtual environment.