ABSTRACT
This chapter deals with a machining operation that reports a different type of problem. This problem is assignable to the different machining operations performed on cast aluminum engine head castings. There were three different cutting operations that were employed to form the end product. One of the serious machining problems encountered while machining grey cast iron or aluminum castings for engine blocks, heads, inlets, or exhaust manifolds is the generation of chips that could become entrained in the component and be released later into a running engine. An inspection of the handling and machining process identified the source of the chips within the head port area. The description of the frequency and identification of flaw presence by machining location can be of great aid to expedite problem solutions. Since different machining operations form different chip sizes and configuration, it may also be used to identify those flaws that are characteristic to a location so that corrective actions can be initiated.
