Proceso de Fabricacin del Monoblock de un Motor

Es el cuerpo del motor

El bloque de cilindros o bloque del motor es una pieza fundida en hierro
o aluminio que aloja los cilindros de un motor de combustin interna as
como los soportes de apoyo del cigeal.
El
monoblock
contiene
internamente a los cilindros, los
pistones, la biela, el eje cigeal,
los engranajes de distribucin,
los buzos, las varillas y la red de
lubricacin.
Externamente
soporta a la bomba de agua, a la
polea, al crter inferior, al
sistema de embrague, al filtro de
aceite, a la bomba de gasolina, al
distribuidor, etc.

Funciones del Monoblock

Adems de alojar los cilindros, donde se
mueven los pistones, el bloque del motor
soporta la culata del motor en la parte superior
y el crter en la parte inferior.
En el interior del bloque existen tambin
cavidades tubulares a travs de las cuales
circula el agua de enfriamiento, as como el
aceite de lubricacin cuyo filtro tambin es
generalmente fijo a la estructura.
El bloque tiene conexiones y aperturas a
travs de las cuales varios otros dispositivos
son controlados a travs de la rotacin del
cigeal

Partes del Monoblock

Bloque, Cilindros o camisas, Empaque de culata Pistones, Anillos, Bulones
Puntos Crticos
Resistencia temperatura: Debido a la combustin dentro del motor la
resistencia a altas temperaturas es necesaria.
Presin: Debido a la situacin ya antes mencionada, la combustin del
combustible presenta altos grados de presin, si la pieza no es
resistente llevara a la fractura de la misma y terminara con su vida til.
Friccin: esta caracterstica es de igual forma muy crtica, al interior del
monoblock se desempean varias actividades, como el desplazamiento
de los pistones, ya estos generan la friccin.
Impacto: va de acuerdo a la resistencia a temperatura y la friccin.
Caractersticas del Monoblock
Las ms importantes se resumen en: gran rigidez y estabilidad
dimensional.
El material del que son construidos los bloques tiene que permitir el
moldeado de todas las aperturas y pasajes indispensables, como
tambin soportar las elevadas temperaturas generadas por la
deflagracin del combustible en el interior del bloque y permitir la rpida
disipacin del calor.
Ventajas y Desventajas
Como desventaja se puede citar la poca rigidez que presenta el bloque
El bloque con cilindro mandrilado tiene la desventaja de no poder
cambiar los cilindros cuando presentan desgaste.
Tiene la ventaja de evitar los riesgos de discontinuidad, desde el punto
de vista trmico, entre el cilindro y el bloque.
Los bloques con camisas permiten la utilizacin de materiales diferentes
en la fabricacin de las camisas, que tienen caractersticas ventajosas
sobre el bloque.

Los bloques con camisas secas tiene la ventaja de mantener la rigidez y

no presentar problemas de estanqueidad.
Los bloque con camisas hmedas tienen la ventaja de presentar ptimas
condiciones de refrigeracin, debido a que la camisa est en contacto
directo con el agua.
Uso y Condiciones de Uso
La bancada principal debe estar alineada.
No debe presentarse fugas por falta de estanqueidad
Las superficies interior y superior deben estar libres de ralladuras y
completamente planas.
Las camisas deben estar dentro de las tolerancias indicadas por el
fabricante, como tambin libres de ralladura y recalentamiento

Precauciones y Limpieza
Precaucin: Las tapas de la bancada principal de un motor no deben ser
usadas en otro bloque, debido a que son mecanizadas conjuntamente.
Lavado solo con agua y jabn despus de un rectificado y no con
derivados del petrleo.

EQUIPOS Y MATERIALES
Material Directo
Aluminio (al): es un metal ligero
- Densidad: 2700 kg/m3, un tercio de la del acero.
- Punto de fusin bajo: 660 C (933 K).

- Resistencia muy baja a la traccin y

una dureza escasa.
Magnesio (mg):
- Densidad: 1738 kg/m3
- Punto fusin: 650 C (923K)
Se fabrica de hierro fundido (hierro
gris) o aleaciones de aluminio.
Tf de hierro fundido (Fe+C): 1250
C
Tf de Aleacin de Aluminio: 800 C
En el Duraluminio, el aluminio
adquiere caractersticas mecnicas superiores.
El Duraluminio:
- Cobre (Cu:3-5%), Magnesio (Mg:0,5-2%),
- Manganeso (Mn: 0,25 - 1%) y Zinc (Zn:3,5 - 5%)

Materiales Indirectos
Arena de Zircon: Es un polvo amorfo, negro-azulado, o un metal brillante blancogrisceo. El zirconio se encuentran en la India, Ucrania, Malasia, Australia, EUA, etc.
La arena de Zirconio presenta excelentes propiedades refractarias,
abrasivas, baja dilatacin trmica y elevada conductividad trmica.
Su composicin es Silicato de circonio (ZrSiO4) y tiene una densidad
aparente aproximada de 2,7 gr/c.c. Su temperatura de fusin es 2420C.
Cola: La cola es el primer elemento que se combina con la arena de zircon para que esta
adquiera forma del molde maestro, dicho pegamento esta diseado para unir los corazones
de arena y afianzarlos dentro del molde.
Endurecedor: El endurecedor se emplea para solidificar la mezcla, para ello se emplea
un gas que lo va a activar para que pueda endurecer el molde.

Polvo de Talco: El polvo de talco es empleado para evitar que las partculas de arena
se peguen al aluminio o al molde final.
PROCESO DE PRODUCCION
Tipo de Fundicin
Fundicin a presin: En el proceso por fundicin a presin, el metal
fundido es obligado a fluir hacia arriba por presin de gas en un molde
de grafito o de metal y es mantenida hasta que el metal se haya
solidificado totalmente dentro del molde.
Este procedimiento es utilizado para fundiciones de alta calidad

Diagrama de flujo

DOP (Diagrama de operaciones)

Planos

Maquinaria requerida para el proceso de fabricacin e un monoblock

AMEF DE DISEO DE MONOBLOCK

ACTIVIDAD
FALLA POTENCIAL
EFECTOS POTENCIALES DE LA FALLA
SEVERIDAD
CAUSA POTENCIAL DE LA FALLA
OCURRENCIA
NIVEL DE PRIORIDAD DE RIESGO
CLASIFICACION

CODIGO DEL PROYECTO

PROYECTO
N
o

DESCRIPCION

ACTIVIDAD

FALLA
POTENCIAL

EFECTOS
POTENCIALES
DE LA FALLA

SEVERID
AD

CAUSA
POTENCIAL
DE LA
FALLA

OCURREN
CIA

DET

MONOBLO
CK

FISURAS,

PUEDE
ROMPERSEY
TERMINA SU
VIDA UTIL

PRESION,
TEPERATUR
A

NIVEL
DE
PRIORID
AD DE
RIESGO
21

DEFORMACION
ES

PROBLEMAAS
AL MOMENTO
DE
ENSAMBLAR
CON OTRAS

48

ERROR EN
LAS
ALEACIONE
S

CLASIFICACI
ON

PIEZAS

35

196

7
NO CUMPLIR
CON LAS
ESPECIFICACIO
NES

FALLA EN LA
CALIDAD DEL
RODUCTO
TERMINADO
4

POCA RIGIDEZ
EN EL BLOQUE
SUPERFICIES
LIBRES DE
RAYADURAS Y
COMPLETAMEN
YTE PLANAS

ERROR EN
LA
RECOLECCI
ON DE
DATOS

QUEBRADURA
S

24
4

LAS CAMISAS
NO
ENSAMBLARIA
N
CORRECTAME
NTE

3
ERROR EN
LA
TEMPERATU
RA
ERROR EN
MEDIDAS Y
ALEACIONE
S

A-1 DESIGN FMEA CHE

Customer or Internal Part No.
Question

Yes

Was the SFMEA and/or DFMEA prepared using the Chrysler, Ford and General Motors
Potential Failure Mode and Effects Analysis (FMEA) reference manual?

Have Historical campaign and warranty data been reviewed?

3
4

Have similar part DFMEAs been considered?

Does the SFMEA and/or DFMEA identify Special Characteristics?

Have design characteristics that affect high risk priority failure modes been identified?

Have appropriate corrective actions been assigned to high risk priority numbers?

Have appropriate corrective actions been assigned to high severity numbers?

Have risk priorities been revised when corrective actions have been completed and verified?

A-2 DESIGN INFORMATION

Customer or Internal Part No.
Question

A. GENERAL
Does the
design require:
1
2
3

New Materials?
Special Tooling?
Has assembly build variation analysis been considered?

4
5
6
7

Has Design of Experiments been considered?

Is there a plan for prototypes in place?
Has a DFMEA been completed?
Has a DFMA been completed?

Yes

Have service and maintenance issues been considered?

9
10
11

Has Design Verification Plan been completed?

If yes, was it completed by a cross functional team?
Are all specified tests, methods, equipment and acceptance criteria clearly defined and
understood?

12

Have Special Characteristics been selected?

A-2 DESIGN INFORMATION CHECK

Customer or Internal Part No.
Question

A. GENERAL
CONTINUED
13
14

Is bill of material complete?

Are Special Characteristics properly documented?

B. Engineering
Drawings
15

Have dimensions that affect fit, function and durability been identified?

16

Are reference dimensions identified to minimize inspection layout time?

17

Are sufficient control points and datum surfaces identified to design functional gages?

18

Are tolerances compatible with accepted manufacturing standards?

19

Are there any requirements specified that cannot be evaluated using known inspection
techniques?

C. Engineering Performance Specifications

20
21

Have all special characteristics been identified?

Is test loading sufficient to provide all conditions, i.e., production validation and end use?

22

Have parts manufactured at minimum and maximum specifications been tested?

Yes

23

Can additional samples be tested when a reaction plan requires it, and still conduct regularly
scheduled in-process tests?

24
25

Will all product testing be done in house?

If not, is it done by an approved subcontractor?

A-2 DESIGN INFORMATION CHECK

Customer or Internal Part No.
Question

C. Engineering
Performance
Specifications continued
26 Is the specified test sampling size and/or frequency feasible?

27 If required, has customer approval been obtained for test equipment?

D. Material Specification
28

Are special material characteristics identified?

Yes

29

Are specified materials, heat treat and surface treatments compatible with the durability
requirements in the identified environment?

30

Are the intended material suppliers on the customer approved list?

31

Will material suppliers be required to provide certification with each shipment?

32

Have material characteristics requiring inspection been identified?

33
34
35

If so,
* Will characteristics be checked in-house?
* Is test equipment available?
* Will training be required to assure accurate
results?

36
37

Will outside laboratories be used?

Are all laboratories used accredited (if required)?

A-2 DESIGN INFORMATION CHECK

Customer or Internal Part No.
Question

Yes

D. Material
Specification continued
Have the following material requirements been considered:
38
* Handling?
39
* Storage?
40
* Environment?

A-3 NEW EQUIPMENT, TOOLING, AND TEST

Customer or Internal Part No.

Question

Yes

Has tool and

equipment design
provided for:
1
* Flexible Systems, e.g. cell mfg.?
2
* Quick change?
3
* Volume fluctuations?
4
* Mistake proofing?
Have lists been prepared identifying:
5
* New equipment?
6
* New tooling?
7
* New test equipment?
Has acceptance criteria been agreed upon for:
8
9
10
11
12

* New equipment?
* New tooling?
* New test equipment?
Will a preliminary capability study be conducted at the tooling and/or equipment
manufacturer?
Has test equipment feasibility and accuracy been established?

13

Is a preventative maintenance plan complete for equipment tooling?

14

Are setup instructions for new equipment and tooling complete and understandable?

A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUI

Customer or Internal Part No.
Question

15

Will capable gages be available to run preliminary process capability studies at the equipment
suppliers facility?

16

Will preliminary process capability studies be run at the producing plant?

17

Have process characteristics that affect special product characteristics been identified?

18

Were special product characteristics used in determining acceptance criteria?

Yes

19

Does the manufacturing equipment have sufficient capacity to handle forecasted production
and service volumes?

20

Is testing capacity sufficient to provide adequate testing?

A-4 PRODUCT/PROCESS QUALI

Customer or Internal Part No.
Question

Yes

Is the assistance of the customer's quality assurance or product engineering activity needed to
develop or concur to the control plan?

Has the supplier identified who will be the quality liason with the customer?

Has the supplier identified who will be the quality liason with the suppliers?

Has the quality system been reviewed using the Chrysler, Ford, and General Motors Quality
System Assessment?

Are there sufficient personnel identified to cover:

5
* Control plan requirements?
6
* Layout inspection?
7
* Engineering performance testing?
8
* Problem resolution analysis?
Is there a documented training program that:
9
* Includes all employees?
10
* Lists whose been trained?
11
* Provides a training schedule?
Has training been completed for:
12

Statistical Process Control?

A-4 PRODUCT/PROCESS QUALITY CH

Customer or Internal Part No.

Question

Yes

Has training been completed for: - CONTINUED

13
14
15
16
17

* Capability studies?
* Problem solving?
* Mistake proofing?
* Other topics as identified?
Is each operation provided with process instructions that are keyed to the control plan?

18

Are standard operator instructions available at each operation?

19

Were operator/team leaders involved in developing standard operator instructions?

Do inspection instructors include:

20

21
22
23
24
Are visual aids:
25
26

Easily understood engineering performance

specifications?

*
*
*
*

Test frequencies?
Sample sizes?
Reaction plans?
Documentation?

*
*

Easily understood?
Available?

A-4 PRODUCT/PROCESS QUALITY CH

Customer or Internal Part No.
Question
Are visual aids: - CONTINUED
27
28
29
30

* Accessible?
* Approved?
* Dated and current?
Is there a procedure to implement, maintain, and establish reaction plans for statistical control
charts?

31

Is there an effective root cause analysis system in place?

Yes

32

Have provisions been made to place the latest drawings and specifications at the point of
inspection?

33

Are forms/logs available for appropriate personnel to record inspection results?

Have provisions been made to place the following at the monitored operation:
34
35
36
37
38

*
*
*
*
*

Inspection gages?
Gage instructions?
Reference Samples?
Inspection logs?
Have provisions been made to certify and
routinely calibrate gages and test equipment?
Have required measurement system capability studies been:
39

Completed?

A-4 PRODUCT/PROCESS QUALITY CH

Customer or Internal Part No.
Question
Have required measurement system capability studies been: - CONTINUED
40
41

* Acceptable?
Are layout inspection equipment and facilities adequate to provide initial and ongoing layout of
all details and components?

Is there a procedure for controlling incoming products that identifies:

42
* Characteristics to be inspected?
43
* Frequency of inspection?
44
* Sample size?
45
* Designated location for approved product?
46
* Disposition of nonconforming products?
47
Is there a procedure to identify, segregate and control nonconforming products to prevent
shipment?
48
49

Are rework/repair procedures available?

Is there a procedure to requalify repair/reworked material?

50
51

Is there an appropriate Lot Traceability system?

Are periodic audits of ongoing products planned and implemented?

Yes

52

Are periodic surveys of the quality system planned and implemented?

53

Has the customer approved the packaging specification?

A-5 FLOOR PLAN CHEC

Customer or Internal Part No.
Question

Yes

Does the floor plan identify all required process and inspection points?

Have clearly marked areas for all material, tools, and equipment?

3
Has sufficient space been allocated?
Are process and inspection areas:
4
* Of adequate size?
5
* Properly lighted?
6
Do inspection areas contain necessary equipment and files?
Are there adequate:
7
8
9

* Staging areas?
* Impound areas?
Are inspection points logically located to prevent shipment of nonconforming products?

10

Have controls been established to eliminate the potential for an operation, including outside
processing, to contaminate or mix similar products?

11

Is material protected from overhead or air handling systems contamination?

A-5 FLOOR PLAN CHECKLIST

Customer or Internal Part No.
Question

Yes

12
13

Have final audit facilities been provided?

Are controls adequate to prevent movement of nonconforming incoming material to storage or
point of use?

A-6 PROCESS FLOW CHART

Customer or Internal Part No.
Question

Yes

Does the floor chart illustrate the sequence of production and inspection stations?

Were all the appropriate FMEAs (SFMEA, DFMEA) available and as aids to develop the
process flow chart?

Is the flow chart keyed to product and process checks in the control plan?

4
5

Does the flow chart describe how the product will move, i.e., roller conveyor, slide containers,
etc.?
Has the pull system/optimization been considered for this process?

Have provisions been made to identify and inspect reworked products before being used?

Have potential quality problems due to handling and outside processing been identified and
corrected?

A-7 PROCESS FMEA CHE

Customer or Internal Part No.
Question

Was the Process FMEA prepared using the Chrysler, Ford, and General Motors guidelines?

Yes

Have all operations affecting fit, function, durability, governmental regulations and safety been
identified and listed sequentially?

3
4

Were similar part FMEAs considered?

Have historical campaign and warranty data been reviewed?

Have appropriate corrective actions been planned or taken for high risk priority numbers?

Have appropriate corrective actions been planned or taken for high severity numbers?

Were risk priority numbers revised when corrective action was completed?

Were high severity numbers revised when a design change was completed?

9
10

Do the effects consider the customer?

Was warranty information used as an aid in developing the process FMEA?

11

Were customer plant problems used as an aid in developing the process FMEA?

12

Have the causes been described in terms of something that can be fixed or controlled?

13

Where detection is the major factor, have provisions been made to control the cause prior to the
next operation?

A-8 CONTROL PLAN CHE

Customer or Internal Part No.
Question

Was the control plan methodology referenced in section 6 used in preparing the control plan?

Have all known customers concerns been identified to facilitate the selection of special
product/process characteristics?

Are all special product/process characteristics included in the control plan?

Were SFMEA, DFMEA, and PFMEA used to prepare the control plan?

Are material specifications requiring inspection identified?

Yes

Does the control plan address incoming (material/components) through processing/assembly

including packaging?

Are engineering performance testing requirements identified?

Are gages and test equipment available as required by the control plan?

If required, has the customer approved the control plan?

10

Are gage methods compatible between supplier and customer?

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