Design and Fabrication of a Cylinder Block Polishing Machine

Abstract

This study presents the design and fabrication of a cylinder block polishing machine using locally available materials to complement conventional cylinder block boring operations in the automobile industry. The machine is powered by a 0.5 HP electric geared motor, which transmits torque through a belt drive system to a rotating shaft. Polishing is achieved using a pair of abrasive stones mounted on a movable base, with a threaded adjustment mechanism for controlling stone width and a stopper for regulating vertical travel within the cylinder bore. Performance evaluation of the developed machine was carried out based on the dimensional accuracy of the polished cylinder bore. Measured diameters obtained under varying initial error conditions ranged from 87.60 mm to 88.35 mm, with an average polished diameter of 87.975 mm compared to a target diameter of 87.85 mm. This corresponds to a deviation of 0.125 mm and a dimensional accuracy of approximately 99.86%, indicating a high level of precision in material removal and geometric conformity. The results demonstrate that the machine is capable of achieving consistent bore finishing within acceptable tolerance limits. However, parameters such as surface roughness, vibration level, noise emission, and temperature rise were not quantitatively measured and therefore require further investigation. The developed machine provides a cost-effective solution for improving dimensional accuracy in cylinder block finishing operations, particularly in resource-constrained environments.