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ing (no loose or lost cores) relies on casting dams the full depth of the water jacket chan- nel (Fig. 3). T ese dams


form the neces- sary strengthening bridges between the cylinder bores and the peripheral body (Fig. 4). If left as


Fig. 6. The orbital movement of a woodruff cutter below the plane of the head deck connects the water jacket segments.


formed, these dams would block the fl ow path of the coolant along the length of the engine in the water jacket channel (refer to the desired coolant fl ow shown in Fig. 1). It is a subsequent machining step


Fig. 5. The remaining need for a successful HPDC engine design is opening a fl ow path to let water move around all cylinder bores. This is done by gaining machining access via frost plug openings (shown above) and using orbital movement of a woodruff cutter below the plane of the head deck to connect the water jacket channel segments, as shown in Fig.6.


that transforms the dams into bridges, providing closed deck-style cylinder


support while allowing the coolant to fl ow unobstructed below the bridges and along the cylinder walls. The machining to remove the coolant-blocking portion of the


aluminum dams is done through openings in the side faces of the engine block (Fig. 5). To mini- mize the diameter of the holes, a woodruff style “T” cutter geom-


etry is used (Fig. 6). This preserves the valuable surface area on the sides of the block for mounting bosses and cast-in features while stiffening the area of connection to


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