某發(fā)動(dòng)機(jī)缸體曲軸孔激光漲斷加工工藝及質(zhì)量控制研究
發(fā)布時(shí)間：2018-08-30 14:13
【摘要】：缸體曲軸孔是發(fā)動(dòng)機(jī)中的重要結(jié)構(gòu),大多數(shù)國(guó)內(nèi)發(fā)動(dòng)機(jī)生產(chǎn)廠家仍然采用傳統(tǒng)分體式加工方法加工缸體曲軸孔,這種方法需要單獨(dú)鑄造、加工缸體、曲軸箱兩個(gè)部件,工藝復(fù)雜,加工成本高,曲軸孔合箱定位精度較差,并且發(fā)動(dòng)機(jī)性能及使用壽命受到限制。與傳統(tǒng)分體式加工工藝相比,激光漲斷工藝的工藝路線簡(jiǎn)單,可以大量縮減加工工序、減少加工設(shè)備用量,并且曲軸孔座與瓦蓋定位精度、裝配質(zhì)量大幅提高,極大提升了曲軸孔合箱后的承載、抗剪切能力,對(duì)提高發(fā)動(dòng)機(jī)整機(jī)性能具有重要作用。另外漲斷技術(shù)可以減少機(jī)加工序60%,節(jié)省機(jī)床設(shè)備投資25%,減少刀具費(fèi)用35%,節(jié)省能源40%,還可以減少占地面積、減少?gòu)U品率等,經(jīng)濟(jì)效益可觀。因此發(fā)動(dòng)機(jī)缸體曲軸孔漲斷加工是大勢(shì)所趨,但目前國(guó)內(nèi)的漲斷加工工藝水平并不成熟,實(shí)際生產(chǎn)中還存在撕裂、裂不開(kāi)、掉渣、斷裂面變形等漲斷缺陷,影響產(chǎn)品質(zhì)量穩(wěn)定性。鑒于上述原因,本課題以某工廠MC系列大功率發(fā)動(dòng)機(jī)的蠕墨鑄鐵材料缸體作為研究對(duì)象,研究缸體曲軸孔激光漲斷加工工藝,對(duì)ALFING激光漲斷設(shè)備進(jìn)行介紹和分析,并對(duì)實(shí)際生產(chǎn)過(guò)程中遇到的質(zhì)量問(wèn)題進(jìn)行深入分析和追蹤。主要內(nèi)容包括:(1)對(duì)MC系列發(fā)動(dòng)機(jī)缸體蠕墨鑄鐵材料的成分特點(diǎn)及力學(xué)性能進(jìn)行了基本介紹,對(duì)曲軸孔分離加工用的ALFING激光漲斷設(shè)備的構(gòu)建,曲軸孔漲斷的工藝特點(diǎn)、技術(shù)要求和典型缺陷進(jìn)行了初步介紹。(2)介紹了ALFING設(shè)備高能激光的產(chǎn)生過(guò)程,詳細(xì)闡述了激光的產(chǎn)生及控制的原理,對(duì)本課題采用的某工廠激光刻痕設(shè)備進(jìn)行了系統(tǒng)說(shuō)明,并結(jié)合該設(shè)備闡述了激光刻痕實(shí)現(xiàn)的方法及過(guò)程,同時(shí)闡述了激光脈沖參數(shù)對(duì)于漲斷槽影響。(3)研究曲軸孔漲斷實(shí)際生產(chǎn)過(guò)程中遇到的質(zhì)量問(wèn)題,以曲軸孔漲斷后掉渣比率過(guò)高問(wèn)題為切入點(diǎn),對(duì)導(dǎo)致漲斷面掉渣的因素通過(guò)六西格瑪質(zhì)量改進(jìn)工具進(jìn)行分析、優(yōu)化的過(guò)程進(jìn)行了詳細(xì)介紹。通過(guò)頭腦風(fēng)暴法、利用魚(yú)骨圖工具、DOE實(shí)驗(yàn)方法等,識(shí)別出導(dǎo)致曲軸孔漲斷面掉渣的關(guān)鍵影響因素,并對(duì)其進(jìn)行改善。并對(duì)改善后的質(zhì)量狀態(tài)、經(jīng)濟(jì)效益進(jìn)行了跟蹤確認(rèn)。本文研究、分析了大功率發(fā)動(dòng)機(jī)蠕墨鑄鐵材料缸體,在利用激光漲斷技術(shù)進(jìn)行曲軸孔的分離加工過(guò)程中出現(xiàn)的典型問(wèn)題,對(duì)某工廠MC系列發(fā)動(dòng)機(jī)提升產(chǎn)品質(zhì)量、保障產(chǎn)品在國(guó)內(nèi)乃至世界的領(lǐng)先地位,有著重要作用,同時(shí)對(duì)于國(guó)內(nèi)的激光漲斷技術(shù)研究及同類發(fā)動(dòng)機(jī)缸體曲軸孔的加工制造及質(zhì)量控制具有一定的參考意義。
[Abstract]:The cylinder crankshaft hole is an important structure in the engine. Most domestic engine manufacturers still use the traditional split machining method to process the cylinder crankshaft hole. The process is complicated, the machining cost is high, the positioning accuracy of the crankshaft closing box is poor, and the engine performance and service life are limited. Compared with the traditional separate processing technology, the laser rising and breaking process is simple, can greatly reduce the processing process, reduce the amount of processing equipment, and the crankshaft hole seat and tile cover positioning accuracy, assembly quality greatly improved. It greatly improves the bearing capacity and shear resistance of the crankshaft closed box, and plays an important role in improving the performance of the engine. In addition, the rising and breaking technology can reduce the machining sequence 60, reduce the investment of machine tools and equipment by 25%, reduce the cost of cutting tools by 35%, save energy and 40% of energy, reduce the area of land, reduce the rate of waste products, etc., and the economic benefits are considerable. Therefore, the expansion and fracture processing of engine cylinder crankshaft holes is the trend of the times, but at present, the domestic rising and breaking processing technology level is not mature, and in actual production, there are still rising and breaking defects, such as tearing, cracking, slag dropping, fracture surface deformation, etc. Affect product quality stability. In view of the above reasons, this subject takes the vermicular graphite cast iron cylinder block of MC series high power engine in a certain factory as the research object, studies the processing technology of the cylinder crankshaft hole laser rising and breaking, and introduces and analyzes the ALFING laser rising and breaking equipment. And the actual production process encountered quality problems in-depth analysis and tracking. The main contents are as follows: (1) the composition characteristics and mechanical properties of MC series engine cylinder block vermicular graphite cast iron are introduced. The construction of ALFING laser breaking equipment for crankshaft hole separation and the technological characteristics of crankshaft hole breaking are introduced. The technical requirements and typical defects are introduced preliminarily. (2) the production process of high-energy laser in ALFING equipment is introduced. The principle of laser generation and control is described in detail. Combined with the equipment, the method and process of laser mark realization are described, and the influence of laser pulse parameters on the expansion and fracture slot is also expounded. (3) the quality problems encountered in the actual production process of crankshaft hole swelling and breaking are studied. Based on the problem of too high slag drop ratio after crankshaft hole breaking, the factors leading to slag drop in rising section are analyzed by six Sigma quality improvement tool, and the process of optimization is introduced in detail. By using the brainstorming method and the fish bone map tool DOE, the key influencing factors that cause the dross drop from the crankshaft hole are identified and improved. The improved quality state and economic benefit are confirmed by tracking. In this paper, the typical problems in the separation and processing of crankshaft holes by using laser bulging technology are studied and analyzed, and the quality of MC series engines in a certain factory is improved by analyzing the cylinder block of vermicular graphite cast iron for high power engine. It plays an important role in ensuring the leading position of products in China and even in the world. At the same time, it has a certain reference significance for the research of laser bulging technology and the manufacture and quality control of crankshaft holes in the same engine block.
【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TK403;TN249
本文編號(hào)：2213315
[Abstract]:The cylinder crankshaft hole is an important structure in the engine. Most domestic engine manufacturers still use the traditional split machining method to process the cylinder crankshaft hole. The process is complicated, the machining cost is high, the positioning accuracy of the crankshaft closing box is poor, and the engine performance and service life are limited. Compared with the traditional separate processing technology, the laser rising and breaking process is simple, can greatly reduce the processing process, reduce the amount of processing equipment, and the crankshaft hole seat and tile cover positioning accuracy, assembly quality greatly improved. It greatly improves the bearing capacity and shear resistance of the crankshaft closed box, and plays an important role in improving the performance of the engine. In addition, the rising and breaking technology can reduce the machining sequence 60, reduce the investment of machine tools and equipment by 25%, reduce the cost of cutting tools by 35%, save energy and 40% of energy, reduce the area of land, reduce the rate of waste products, etc., and the economic benefits are considerable. Therefore, the expansion and fracture processing of engine cylinder crankshaft holes is the trend of the times, but at present, the domestic rising and breaking processing technology level is not mature, and in actual production, there are still rising and breaking defects, such as tearing, cracking, slag dropping, fracture surface deformation, etc. Affect product quality stability. In view of the above reasons, this subject takes the vermicular graphite cast iron cylinder block of MC series high power engine in a certain factory as the research object, studies the processing technology of the cylinder crankshaft hole laser rising and breaking, and introduces and analyzes the ALFING laser rising and breaking equipment. And the actual production process encountered quality problems in-depth analysis and tracking. The main contents are as follows: (1) the composition characteristics and mechanical properties of MC series engine cylinder block vermicular graphite cast iron are introduced. The construction of ALFING laser breaking equipment for crankshaft hole separation and the technological characteristics of crankshaft hole breaking are introduced. The technical requirements and typical defects are introduced preliminarily. (2) the production process of high-energy laser in ALFING equipment is introduced. The principle of laser generation and control is described in detail. Combined with the equipment, the method and process of laser mark realization are described, and the influence of laser pulse parameters on the expansion and fracture slot is also expounded. (3) the quality problems encountered in the actual production process of crankshaft hole swelling and breaking are studied. Based on the problem of too high slag drop ratio after crankshaft hole breaking, the factors leading to slag drop in rising section are analyzed by six Sigma quality improvement tool, and the process of optimization is introduced in detail. By using the brainstorming method and the fish bone map tool DOE, the key influencing factors that cause the dross drop from the crankshaft hole are identified and improved. The improved quality state and economic benefit are confirmed by tracking. In this paper, the typical problems in the separation and processing of crankshaft holes by using laser bulging technology are studied and analyzed, and the quality of MC series engines in a certain factory is improved by analyzing the cylinder block of vermicular graphite cast iron for high power engine. It plays an important role in ensuring the leading position of products in China and even in the world. At the same time, it has a certain reference significance for the research of laser bulging technology and the manufacture and quality control of crankshaft holes in the same engine block.
【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級(jí)別】：碩士
【學(xué)位授予年份】：2017
【分類號(hào)】：TK403;TN249
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，本文編號(hào)：2213315
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