Abstract: A thermally sprayed coating is formed on an inner surface of a cylinder bore of a cylinder block by using a thermal spray gun. The thermal spray gun is reciprocated along an axial direction in the cylinder bore while being rotated, and injects melted droplets generated by melting a wire made of a ferrous material from a nozzle at its end. At this time, a moving speed of the thermal spray gun along the axial direction into the cylinder bore is made equal-to or larger-than a predetermined value, and the number of reciprocating cycles of the thermal spray gun along the axial direction into the cylinder bore is made equal-to or larger-than a predetermined value.

Abstract: In a method for manufacturing a cylinder block provided with cylinder bores, the cylinder block is held by a clamp device, stress is generated in the cylinder block by a holding force of the clamp device to duplicate deformations of the cylinder bores after assembling hearing caps thereon, boring is carried out with the cylinder bores deformed in a condition where the stress is generated, and a thermally sprayed coating is formed, after the boring, on each inner surfaces of the cylinder bores deformed in the condition where the stress is generated. According to the method for manufacturing a cylinder block, superior cylindricity, after assembling the bearing caps, of the cylinder bores on each of which the thermally sprayed coating is formed can be brought, and workability degradation of finishing works (honing) for each inner surface of the cylinder bores (thermally sprayed coatings) can be restricted.

Abstract: A cylinder block manufacturing method including: machining an inner surface of a cylinder bore (3) of a cylinder block (1) into a first shape different from a target shape before a bearing cap (7) is attached to the cylinder block (1) so that the inner surface of the cylinder bore (3) is deformed into the target shape by attachment of the bearing cap (7) to the cylinder block (1); and forming a thermal spray coating (5) on the inner surface of the cylinder bore (3) having the first shape.

Abstract: A cylinder block manufacturing method including: machining an inner surface of a cylinder bore (3) of a cylinder block (1) into a first shape different from a target shape before a bearing cap (7) is attached to the cylinder block (1) so that the inner surface of the cylinder bore (3) is deformed into the target shape by attachment of the bearing cap (7) to the cylinder block (1); and forming a thermal spray coating (5) on the inner surface of the cylinder bore (3) having the first shape.

Abstract: In a method for manufacturing a cylinder block provided with cylinder bores, the cylinder block is held by a clamp device, stress is generated in the cylinder block by a holding force of the clamp device to duplicate deformations of the cylinder bores after assembling hearing caps thereon, boring is carried out with the cylinder bores deformed in a condition where the stress is generated, and a thermally sprayed coating is formed, after the boring, on each inner surfaces of the cylinder bores deformed in the condition where the stress is generated. According to the method for manufacturing a cylinder block, superior cylindricity, after assembling the bearing caps, of the cylinder bores on each of which the thermally sprayed coating is formed can be brought, and workability degradation of finishing works (honing) for each inner surface of the cylinder bores (thermally sprayed coatings) can be restricted.

Abstract: A thermally sprayed coating is formed on an inner surface of a cylinder bore of a cylinder block by using a thermal spray gun. The thermal spray gun is reciprocated along an axial direction in the cylinder bore while being rotated, and injects melted droplets generated by melting a wire made of a ferrous material from a nozzle at its end. At this time, a moving speed of the thermal spray gun along the axial direction into the cylinder bore is made equal-to or larger-than a predetermined value, and the number of reciprocating cycles of the thermal spray gun along the axial direction into the cylinder bore is made equal-to or larger-than a predetermined value.

Abstract: A plating layer 18 of Ni or the like is formed around the outer peripheral face 14 of a wire tool 10, and super abrasive grains 16 are electrodeposited so as to be embedded in the plating layer 18. A coating layer 20 is formed on the surface of the super abrasive grains 16 to increase efficiency during electrodeposition. The thickness of the coating layer 20 formed on the super abrasive grains 16 is less than 0.1 ?m, and preferably not more than 0.05 ?m. The coating layer 20 is thin enough that its mass is less than 10% of the mass of the super abrasive grain 16. Accordingly, the super abrasive grains 16 are electrodeposited in a single layer around the outer peripheral face 14 of the core wire 12. As a result, the super abrasive grains 16 do not readily come off the core wire 12, which means that the wire tool will have a longer life. Also, since there is no need to remove any excess super abrasive grains after their electrodeposition, manufacturing costs can be cut and less work is entailed.

Abstract: A plating layer 18 of Ni or the like is formed around the outer peripheral face 14 of a wire tool 10, and super abrasive grains 16 are electrodeposited so as to be embedded in the plating layer 18. A coating layer 20 is formed on the surface of the super abrasive grains 16 to increase efficiency during electrodeposition. The thickness of the coating layer 20 formed on the super abrasive grains 16 is less than 0.1 ?m, and preferably not more than 0.05 ?m. The coating layer 20 is thin enough that its mass is less than 10% of the mass of the super abrasive grain 16. Accordingly, the super abrasive grains 16 are electrodeposited in a single layer around the outer peripheral face 14 of the core wire 12. As a result, the super abrasive grains 16 do not readily come off the core wire 12, which means that the wire tool will have a longer life. Also, since there is no need to remove any excess super abrasive grains after their electrodeposition, manufacturing costs can be cut and less work is entailed.