FORM - 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patents Rules 2003
COMPLETE SPECIFICATION
(SECTION 10 & rule 13)
TITLE
Process and tooling for manufacturing cylinder head Integrated with intake manifold
APPLICANT
We, Bajaj Auto Limited, an Indian Company, having its registered office at Akurdi, Pune - 411 035, State of Maharashtra, India.
The following specification describes and ascertains the nature of this invention and the manner in which it is to be performed:-

Process and tooling for Manufacturing cylinder head Integrated with intake manifold-Field of invention.
This invention is related to process of producing or manufacturing of cylinder head integrated with intake manifold. The invention also related to tooling used for manufacturing the cylinder head integrated with intake manifold. Background
IC engines comprises of parts like cylinder head, block carburettor, intake manifold etc. While assembling the engine, the intake manifold through its flange portion is assembled to intake port of the cylinder head using suitable fastening means or arrangement. The intake manifold is provided with a groove to accommodate or clamp rubber insulator through which intake manifold is connected to carburettor. The air fuel mixture from carburettor is supplied to combustion chamber through this rubber insulator.
There are problems associated with the above type of assembly. One of the problems associate with mismatching of profile of connecting surfaces or portions of intake manifold and intake port of cylinder head. This mismatching at joining or connecting portion leads to creation of turbulence in air /fuel supply path, thereby hampering the efficiency of the engine. Another problem associated with this is that as the cylinder head and intake manifold are produced by independent process, the internal surface pattern of intake manifold and intake port is different, this does not facilitate smooth flow of air fuel mixture. This again may lead to reduce efficiency of engine. Hence, to prevent above said problems, it is advisable to integrate the intake manifold with cylinder head during manufacturing itself.
Attempts have been made in past to integrate the intake manifold with cylinder head. However, the attempts teach that the integrated manifold is produced through some casting process like GDC

(Gravity dies casting), which is time consuming, costly process and gives less yield. To that extent LPDC (low pressure die casting method may be employed.
As a general practice, the LPDC process used to produce cylinder head use arrangement of six die blocks comprising four sliding die blocks other than one stationary die block & one moving die block. However, in case of manufacturing the cylinder head integrated with intake manifold with groove, it is not possible to produce with four sliding die blocks, the reason being that the protruding portion of intake manifold and groove required on the intake manifold do not allow this process .This is because the reason that the sliding block which produces the intake manifold and its groove does not allow any die block moving in the direction parallel to axis of manifold as this movement generates defects like undercutting .Further, the sliding block which moves parallel to intake manifold does not allow sufficient passage for air vents for escape route of air, this cause under filling at the portion of intake manifold wall and the component gets rejected. Also, the sliding die block which generates groove while inward position produces defect like undercut while on return path. Moreover, this six slide die block process used to manufacture integrated cylinder head with intake manifold (with groove or without groove) may raise difficulties like unfiling due to insufficient air venting & early metal solidification of metal at the cavity portion of intake manifold.
The sliding blocks for producing intake manifold and other parts of cylinder head are stack of plates assembled together or a solid block.
There is always a limitation or constraint for the length of these stacks, especially when these stacks are thin and producing or casting a thin surface . The more length of the stacks causes their frequent breakage during casting process.
Further, it does not allow sufficient air venting provision. Also, it extracts more heat from metal where the area or surface to be casted is thin for example the intake manifold wall portion & its groove and fin structure of cylinder head which causes early metal solidification at thin portions.

Hence thin wall portion of intake manifold & thin wall portion of groove and fins may raise
difficulties like unfilling.
In conclusion, considering the above problems/constraints , it is difficult to produce cylinder head
integrated with intake manifold whether with groove or without groove by using known LPDC
processes.
Even the cylinder head integrated manifofd without comprising groove caffs for machining of
groove subsequent to casting process which require man and machine resources .
Applicant has tried to eliminate limitations and drawbacks of above said prior arts.
Objectives of the invention.
In this view, one objective of the present invention to provide a process and tooling for manufacturing of cylinder head Integrated with intake manifold to improvise productivity, reduce cost of manufacturing and reduction in machining time and optimizing the yield.
It is yet another objective of the invention to provide a process and tooling for manufacturing of cylinder head Integrated with intake manifold comprising groove to improvise productivity, reduce cost of manufacturing and reduction in machining time and optimizing the yield.
Statement of Invention.
A casting process of manufacturing cylinder head Integrated with intake manifold comprising plurality of sliding die blocks and a stationery die block wherein at least one sliding die block & one stationary die block forming the geometry/structure of intake manifold including geometry of other portions of cylinder head surrounding the intake manifold and having their axis substantially perpendicular to the axis of intake port of the cylinder head. The said die blocks may be positioned in the vertical axis or in horizontal axis or in combination. Preferably the casting process used is LPDC.

-preferably the said surrounding portions formed by said die blocks comprise left & right side and top and bottom portions surrounding the intake manifold.
-Preferably said surrounding portions of intake manifold connected to intake manifold produced by said die blocks.
-Preferably the left and right side portions are air passages and fins of cylinder head.
-preferably top and bottom surfaces/portions are flat or hollow surfaces surrounding
the intake manifold. -Preferably the said top & bottom portions and left side and right side portions formed by said die blocks are formed integrated/connected with the said intake manifold.
-preferably , the lower left and right side fins of cylinder head are
integrated/connected with intake manifold.
-prferably the upper portion formed is hollow surface and integrated/connected to
intake manifold through a fin of cylinder head and a lug.
-preferably the lower portion/surface is flat surface substantially matching with lower
portion of intake manifold. -preferably, when two sliding die blocks and one stationery die block are used, the said sliding die blocks are positioned opposite to each other and stationary block is positioned in different axis.
- preferably the said two of the sliding die blocks are positioned in
horizontal axis and stationery die block is positioned in vertical axis. -preferably, when one sliding die block and one stationery die block is used , the said sliding block and stationery blocks are positioned opposite to each other.
-preferably said sliding and stationery die blocks are positioned in vertical axis. -preferably stationery die block is a bottom die block

The above said method or process is capable of producing cylinder head with intake manifold
integrated.
The said method and process is capable of producing intake manifold with groove integrated
with cylinder head.
Tooling for manufacturing cylinder head Integrated with intake manifold by casting process comprising plurality of sliding die blocks and a stationery die block wherein at least one sliding die block & one stationary die block forming the geometry/structure of intake manifold including geometry of other portions of cylinder head surrounding the intake manifold and having their axis substantially perpendicular to the axis of intake port of the cylinder head. The said die blocks may be positioned in the vertical axis or in horizontal axis or in combination. Preferably the casting process used is LPDC.
-preferably the said surrounding portions formed by said die blocks comprise left & right side and top and bottom portions surrounding the intake manifold.
-Preferably said surrounding portions of intake manifold connected to intake manifold produced by said die blocks.
-Preferably the left and right side portions are air passages and fins of cylinder head.
-preferably top and bottom surfaces/portions are flat or hollow surfaces surrounding
the intake manifold. -Preferably the said top & bottom portions and left side and right side portions formed by said die blocks are formed integrated/connected with the said intake manifold.
-preferably , the lower left and right side fins of cylinder head are
integrated/connected with intake manifold.

-prferably the upper portion formed is hollow surface and integ rated/connected to
intake manifold through a fin of cylinder head and a lug.
-preferably the lower portion/surface is flat surface substantially matching with lower
portion of intake manifold. -preferably , when two sliding die blocks and one stationery die block are used, the said sliding die blocks are positioned opposite to each other and stationary block is positioned in different axis.
- preferably the said two of the sliding die blocks are positioned in
horizontal axis and stationery die block is positioned in vertical axis. -preferably, when one sliding die block and one stationery die block is used , the said sliding block and stationery blocks are positioned opposite to each other.
-preferably said sliding and stationery die blocks are positioned in vertical axis.
-preferably stationery die block is a bottom die block
The above said tooling is capable of producing cylinder head with intake manifold integrated. The said tooling is capable of producing intake manifold with groove integrated with cylinder head.
The process and tooling involves either two or three die blocks to form the geometry /shape of the intake manifold with or without groove integrated with cylinder head along with other portions of cylinder head surrounding area of intake manifold. As another aspect of invention, the geometry /shape of the intake manifold may be formed through three die block, two die blocks being positioned in horizontal axis, other being located in vertical axis. Preferably the die blocks located in horizontal axis are sliding blocks and die block positioned in vertical axis is fixed.

Yet, in the another aspect of invention, the geometry /shape of the intake manifold may be formed through two die block, both die blocks being positioned in vertical axis . Preferably one of the die block is sliding die block and other die block is fixed.
Detail Description
The invention is explained in detail with respect to figures and description as below.
Figure 1a shows an isometric view of cylinder head with a separate intake manifold assembled to
it according to prior art .
Figure 1b shows an isometric view of cylinder head according to prior art .
Figure 1c shows an isometric view of prior art separate intake manifold according to prior art .
Figure 2 shows an isometric view of cylinder head with integrated intake manifold without groove
according to one of the embodiment of invention.
Figure 3a shows an isometric view (Left side i.e. spark plug side) of cylinder head with integrated
intake manifold comprising a groove as another embodiment of to invention.
Figure 3b shows a right side or tunnel side isometric view of figure 3a.
Figure 3c shows a Rear side or exhaust port side isometric view of figure 3a
Figure 4 shows an exploded view of die according to one of the embodiment of invention.
Figure 5 shows plan view of die according to one of the embodiment of invention.
Figure 6 shows a cross section of figure 5.
Figure 7 shows detail view of die block for intake manifold with groove.
Figure 8 shows detail view of die block for intake manifold without groove.
Figure 9 shows an isometric view of die according to one of the embodiment of invention.
Figure 10 shows sectional view of fig. 6 for side blocks and bottom block illustrating forming of
intake manifold.
Figure 11 shows sectional view of die according to another embodiment of invention.

Figure 11a shows sectional view figure 11.
Figure 12 shows sectional view of die according to yet another embodiment of invention.
The cylinder head (1) shown in figure 1b requires that an intake manifold ( 2) shown in figure 1c is assembled to it at the intake port (3) of the cylinder head (1) using some fastening arrangement as shown in figure 1a. The said cylinder head (1) and said intake manifold (2) being separately manufactured, so while assembling these two parts it faces the problems like mismatching of profile of connecting portions of intake manifold (2) and intake port (3) of cylinder head (1) leading to creation of turbulence in supply path thereby hampering the efficiency of the engine and as the internal surface pattern of intake manifold and intake port is different, this does not facilitate smooth flow of air fuel mixture. This again may lead to reduce efficiency of engine. The cylinder head (1) can be easily produced through LPDC process by using 6 die blocks (i.e front block .rear block,LHS & RHS die blocks and top & bottom die blocks). One of moving die block forming the intake port 3 and surrounding portion of cylinder head (for example partial portion of fins) can be positioned in the direction parallel to the axis of intake port 3 as shape and structure/geometry of this cylinder head does not has any protruding portion causing any defect like under cut while return path of the die block. Also, as remaining portion of fins of cylinder head formed by other die blocks, this does not call for single die block of comprising stacks of long length producing these fins, hence no issues or problems arise related under filling and breakage of these stacks during operation of casting process.
Figure 2 and 3a shows the cylinder head 100 integrated with intake manifold without groove (10) and with groove (20) respectively manufactured by using process and tooling according to invention which avoid above said problems.
As the manifold is to be integrated with cylinder head, the die block forming this intake manifold can not be positioned and moved in the axis parallel to axis of intake port or intake manifold , the

reason being the die block while on its return path will create an under cut on the intake manifold and groove of the intake manifold.
According to one of the embodiment or aspect of the invention as illustrated in figures 4 to 8, the tooling of the process comprises of three sliding block marked as (21, 22, 23) capable of sliding in horizontal axis, one top sliding block (24) capable of sliding in vertical axis and one fixed bottom block (25). The interior surfaces of these blocks are so designed as to produce required design /shape of the cylinder head when the casting process cycle is operated using these tooling/block. The sliding block (21) is positioned at left hand side and sliding die block (22) is positioned at right hand side when viewed from intake port (i.e. from 'X' direction as illustrated in figure. 3a) of cylinder head (20). The molten material fed through the bottom side of the tooling. The sliding blocks (21 , 22) top block (24 )and bottom block (25) are so designed as produce geometry /shape of spark plug opening (27), chain tunnel area (28) and intake manifo!d(20) and side portions of fins (31, 32) as illustrated in figures 3a and 3b.
The rear block (23) produces the exhaust portion geometry (29) and rear portions of fins (33) as illustrated in figure 3c. The bottom block (25) apart from producing portion of intake manifold produces geometry/shape of combustion chamber (26) as illustrated in figure 3b , The top block creates geometry/shape of rocker cam region (30) as illustrated in figure 3a. It can be observed that from the figure 10 the formation of intake manifold with groove from the sliding blocks (21 , 22) and bottom block (25). The intake sand core (35) required to produce shape of manifold is supported by bottom block (25). The figure 6 and 7 show sectional and detail views for formation of intake manifold and groove (34). The detail view 7 illustrates the shape of die block (22) which forms portion of the groove (34). To avoid the problem of unfilling, a minimal gap say for example 0.2 mm is kept in between mating faces of sliding blocks (21,22) and bottom block (25) for the purpose of air venting. Also the thickness of sliding blocks (21, 22) is kept minimum in this region for less heat extraction from molten metal while cavity filling, as illustrated in figure 10

It can be observed that the axis of sliding block (21, 22) is substantially perpendicular axis of intake manifold (20) in horizontal plane and axis of bottom block (25) and top die block 24 are is- substantially perpendicular axis of intake manifold (20) in vertical plane .These blocks produce the geometry of integrated manifold and parts or portions of cylinders head surrounding the intake manifold. However these angles may be varied depending upon the orientation of intake manifold with respect to cylinder head.
With respect to another aspect or embodiment of the invention as illustrated in figure 11 and 11 a, the formation of intake manifold integrated with cylinder head and portions of cylinder head surrounding cylinder head can be made through, two die blocks (24a, 25a) by making appropriate changes in the shape/design of internal surfaces of these die blocks These die blocks are positioned in vertical axis . The vertical top die block (24a) is moving die block and bottom die block (25a) is fixed. Apart from participating in forming lower portion of the intake manifold, the bottom die block(25a) form the combustion chamber 26 and bottom fin profile. Also it supports the intake sand core (35), exhaust sand core (36), air jacket sand core (37) and chain tunnel sand core (38). The molten material fed through the bottom side of the tooling, The top die block (24a) forms upper portion of intake manifold 20, the Rocker cam region (30) & partial chain tunnel region (28) of cylinder head. The left side block (21a) & right side block (22a) positioned in horizontal axis forms the first spark plug region (27), part of fins (31) and chain tunnel region (28) & part of fins (32) respectively. The rear side block (23) forms the exhaust silencer mounting region (29) & parts of fins (33). Fig 11a illustrates a section view of figure 11 showing the formation of intake manifold 20.
The pertinent faces of die blocks are matched to air jacket sand core (37) to form the air passage openings (39) in the cylinder head part. These openings (39) are required to pass the air through them to cool the engine. These air passage openings are decided as per engine design requirement.

With respect to yet another aspect of the invention as illustrated in figure 12, the formation of intake manifold integrated with cylinder head and portions of cylinder head surrounding the intake manifold can be made through, two slide die blocks (21a, 22a) positioned in horizontal axis by making appropriate changes in the shape/design of internal surfaces of these die blocks. The vertical top die block (24b) is moving die block and bottom die block (25b) is fixed. Apart from forming the intake manifold, the bottom die block (25b) form the combustion chamber and bottom fin profile. Also it supports the intake sand core (35), exhaust sand core (36), air jacket sand core(37) and chain tunnel sand core (38). The molten material fed through the bottom side of the tooling. The top die block (24b) forms the Rocker cam region (30) & partial chain tunnel region (28) of cylinder head. Apart from forming intake manifold (with or without groove),the left side block (21a) & right side block (22a) positioned in horizontal axis form the first spark plug region (27), part of fins(31) and chain tunnel region(28) & part of fins(32) respectively. The rear side block (23) forms the exhaust silencer mounting region (29) & parts of fins (33). The pertinent faces of die blocks are matched to air jacket sand core (37) to form the air passage openings (39) in the cylinder head part. These openings (39) are required to pass the air through them to cool the engine.
. With reference description of the above embodiments of present invention mentioned above, it can be observed that the fin length of fins 40g, 40f,40 d and 40 c produced by the casting processes and die blocks are comparatively less that corresponding fins of cylinder head according to prior art and a hollow surface 30a is generated above the manifold 20 This is achieved by keeping the length of corresponding surface of die block shorter, otherwise more length of die block which is producing fins creates problem under filling and causes breakage of these die blocks .Also, air opening passages 39 generated by the die blocks are more wider compared to cylinder of prior art. Further the gap between lower fins 40a and 40b is filled up by stack of material 40h which is extending parallel to the direction of fin length and connecting intake manifold 20.

The lower surrounding portion of intake is flat surface (40 i) and substantially matches with the lower portion of intake manifold.
The above mentioned features of tooling and die blocks allow the process to happen smoothly without producing any defects like under cut on intake manifold & its groove and unfilling in walls of intake manifold and fins of cylinder head . Further, the geometry and shape of cylinder head integrated with manifold produced with the present tooling and process helps to improve heat transfer efficiency of the cylinder head and also assist in reducing the weight of cylinder. Further, this arrangement of tooling allows use of maximum five die blocks as against use of 6 die blocks according to prior art. Thus , this arrangement allows using of multicavity die set up in which plurality of cylinder heads integrated with manifold can be produced in one cycle of casting process.
Generally, the slide blocks are the assembly of stack plates to form the fins. While the casting process is in progress, air needs to be escaped through this stack of plates. Otherwise the entrapped air will cause back pressure on metal and creates the problem of unfilling Towards this, air vents are needs to be provided on these stack plates. Normally, 'V shape type serrations are provided along the part profile on this stack plates as air vents. However, it is very difficult to clean these V air vents due to bolted assembly of stack plates. This limitations reduces effectiveness of V air vents for thin & long shaped parts.
To avoid this problem, Applicant has maintained a minimal gap say for example 0.2 mm between the mating faces (generally called the parting planes) of slide blocks & fix blocks to pass the air through these gaps while metal filling in the cavity. These mating faces are clearly visible to operator and can be cleaned easily while the die is in open condition, i.e. while all the sliding blocks are in retracted position. This has eliminated the problem of unfilling the intake manifold region.

A typical flow or sequence of the process can be as follows: -
1. Die is in open condition: - all the slide blocks (21, 22, and 23) are in retracted position & top moving die block (24) at top most position.
2. Placement of sand cores: - Placement of Intake (35), exhaust (36), air jacket (37) & chain tunnel (38) sand cores on bottom die block (25).
3. Closing of die: - the entire slide blocks (21, 22, 23) in forward position & top die block (24) in downward position to close the die.
4. Filling molten material: - Low pressure molten metal enters from bottom die block (25) opening to fill the cavity.
5. Cooling: - Time to cool the molten metal to form the solid shape of part as per cavity shape.
6. Opening of die: - all the slide blocks (21, 22, 23) are in retracted position & top moving die block (24) at top most position. Then ejection of casting from top moving die block.
A similar process flow may be employed for other embodiments of invention.
The intake manifold without groove integrated with cylinder head (10) can also be manufactured
with above said process and tooling by doing necessary changes in the internal shape structure of
pertinent die blocks.
The above said process and tooling prevents various parts and machining & assembly operation
required for assembling intake manifold and cylinder head. Also, it improves flow of air/fuel to the
combustion chamber and improves efficiency of engine.
The above said process and tooling is capable of producing any shape of cylinder head integrated
with intake manifold by doing appropriate changes in internal surfaces of die blocks and selecting
suitable combination sliding die block and fixed die block to form required geometry .

Any modifications and variations to the subject invention known to the person skilled in the art are covered under the scope of the invention.

We Claim: 1. A LPDC casting process of manufacturing cylinder head Integrated with intake manifold comprising plurality of sliding die blocks and a stationery die block wherein at least one sliding die block & one stationary die block forming the geometry/structure of intake manifold including geometry of other portions of cylinder head surrounding the intake manifold and said die blocks having their axis substantially perpendicular to the axis of intake port of the cylinder head: 2.A casting process as claimed in claim 1 where in the said die blocks are positioned in the vertical axis or in horizontal axis or in combination.
3. A casting process as claimed in claim 1 wherein the said surrounding portions of intake manifold being left & right side and top and bottom portions surrounding the intake manifold produced by said die blocks .
4.. A casting process as claimed in claim 2 wherein said surrounding portions of intake manifold connected to intake manifold produced by said die blocks.
4. A casting process as claimed in claim 4 wherein the said left and right side portions are air
passages and fins of cylinder head produced by said die blocks -.
5. A casting process as claimed in claim 4 wherein said top and bottom portions are hollow or
flat surfaces surrounding the intake manifold produced by said die blocks -.
6. A casting process as claimed in claim 4 wherein the said upper portion formed by the die
block is hollow surface and integrated/connected to intake manifold through a extended portion of
fin of cylinder head and a lug portion .
7. A casting process as claimed in claim 4 wherein the lower portion/surface is flat surface
substantially matching with lower portion of intake manifold.

8. A LPDC casting process of manufacturing cylinder head Integrated with intake manifold
claimed in any of the preceding claims wherein casting process comprises two sliding die blocks
and one die stationary block.
9. A casting process as claimed in claim 8 wherein said sliding blocks are positioned opposite
to each other in same plane and stationery block is positioned in the plane perpendicular to plane
of sliding die blocks
10 A casting process as claimed in claim 9 wherein said sliding clocks are positioned in horizontal plane and said stationery block is positioned in vertical plane.
11. A casting process as claimed in any of the preceding claims wherein casting process
comprises one sliding die block and one die stationary block.
12. A casting process as claimed in claim 11 wherein said one sliding block and said stationery block are positioned opposite to each other in same plane
13. A casting process as claimed in claim 12 wherein said sliding block and said stationery block are positioned in vertical plane .

14. Tooling for manufacturing cylinder head Integrated with intake manifold by LPDC casting process-comprising plurality of sliding die blocks and a stationery die block wherein at least one sliding die block & one stationary die block forming the geometry/structure of intake manifold including geometry of other portions of cylinder head surrounding the intake manifold and having their axis substantially perpendicular to the axis of intake port of the cylinder head. The said die blocks may be positioned in the vertical axis or in horizontal axis or in combination. Preferably the casting process used is LPDC.
15. Tooling for manufacturing cylinder head Integrated with intake manifold by LPDC casting process as claimed in claim 14 wherein the said surrounding portions of intake manifold being left & right side and top and bottom portions surrounding the intake manifold produced by said die blocks; wherein said surrounding portions of intake manifold connected to intake manifold produced by said die blocks; wherein the said connected left and right side portions are air

passages and fins of cylinder head produced by said die blocks and wherein said integrated or connected top and bottom portions are hollow or flat surfaces surrounding the intake manifold produced by said die blocks ;wherein the said upper portion formed by the die block is hollow surface and integrated or connected to intake manifold through a extended portion of fin of cylinder head and a lug portion ;wherein the lower portion/surface is flat surface substantially matching with lower portion of intake manifold.
16.Tooling for manufacturing cylinder head Integrated with intake manifold by LPDC casting process as claimed in claim 14 wherein casting tooling comprises two sliding die blocks and one die stationary block and wherein said sliding blocks are positioned opposite to each other in same plane and stationery block is positioned in the plane perpendicular to plane of sliding die blocks wherein said sliding clocks are positioned in horizontal plane and said stationery block is positioned in vertical plane.
17. Tooling for manufacturing cylinder head Integrated with intake manifold by LPDC casting process as claimed in claim 14 wherein tooling comprises one sliding die block and one die stationary block wherein said one sliding block and said stationery block are positioned opposite to each other in same plane and wherein said sliding block and said stationery block are positioned in vertical plane .
18. A LPDC casting process and tooling as acclaimed in any of the preceding claims allowing multicavity die set up for producing plurality of cylinder heads integrated with manifold .