Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on an integral crankcase region and one or more locator surfaces on the crankcase region. The barrels are formed by a barrel-forming tool element of a core box. The barrel-forming tool element is configured to also form the locator surface(s) on the crankcase region such that the locator surface(s) is/are accurately positioned relative to the barrels and thus the cylinders formed in the engine block cast in the mold package. The locator surface(s) can be used to locate the engine block casting in subsequent aligning and machining operations without the need to reference a curved surface of a cylinder bore liner.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces contamination of the engine block cast in the mold package by loose sand abraded off the cores during assembly. An assembly of multiple cores (core package) of the engine block mold package is formed apart from a base core. The core package is cleaned to remove loose sand therefrom. The cleaned core package then is positioned on the base core followed by assembly of a cover core to complete the engine block mold package for casting of an engine block therein.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.

Abstract: An engine block mold package includes a barrel crankcase core having a plurality of barrels on an integral crankcase region and one or more locator surfaces on the crankcase region. The barrels are formed by a barrel-forming tool element of a core box. The barrel-forming tool element is configured to also form the locator surface(s) on the crankcase region such that the locator surface(s) is/are accurately positioned relative to the barrels and thus the cylinders formed in the engine block cast in the mold package. The locator surface(s) can be used to locate the engine block casting in subsequent aligning and machining operations without the need to reference a curved surface of a cylinder bore liner.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces contamination of the engine block cast in the mold package by loose sand abraded off the cores during assembly. An assembly of multiple cores (core package) of the engine block mold package is formed apart from a base core. The core package is cleaned to remove loose sand therefrom. The cleaned core package then is positioned on the base core followed by assembly of a cover core to complete the engine block mold package for casting of an engine block therein.

Abstract: An engine block mold package is assembled from resin-bonded sand cores in a manner that reduces parting lines on the exterior surfaces of the mold package. An assembly of multiple cores (core package) is formed and includes multiple inter-core parting lines extending in different directions on exterior surfaces of the core assembly. The core package is disposed between a base core and a cover core configured to enclose the core package and form a single continuous exterior parting line about the assembled mold package.