一种基于堆焊修复的差速器壳体再制造生产线设计研究

发布时间：2018-01-09 05:00

本文关键词：一种基于堆焊修复的差速器壳体再制造生产线设计研究　出处：《广西大学》2015年硕士论文　论文类型：学位论文

【摘要】：再制造具有巨大的资源潜力、显著的经济效益和明显的环保作用,是节能减排大环境下先进制造技术的重要部分和发展方向。差速器总成是工程机械重要的零部件之一,差速器壳体结构和形状复杂,精度高,制造难度大,造价昂贵,是工程机械中具有再制造价值的零部件之一。由于工程机械工作环境的恶劣性和复杂性,差速器在使用过程中,主要零部件会发生磨损、磕碰、断裂等而失效。调研发现,差速器壳体的主要失效形式是磨损,磨损部位是在与半轴齿轮接触的安装面上,磨损失效后的壳体仍具有较大的储备寿命,并具有可行的修复技术方法,可以通过表面工程技术恢复其磨损部位的尺寸,并赋予表面新的性能。为此,以差速器壳体为再制造对象,采用堆焊的再制造技术,设计一条专门针对壳体磨损面修复的高效率、自动化生产线,以取代人工作业,对于降低劳动强度,提高生产效率,实现批量生产,降低生产成本,推动再制造的发展无疑具有很好的现实意义。本文从产品失效模式分析出发,根据差速器壳体的失效特点,确定了利用亚激光瞬间冷焊技术在磨损表面上进行堆焊的再制造工艺方案,进行了专门针对差速器壳体磨损修复的再制造生产线的设计。该设计力求结合生产实际,在进行车间工艺设计和平面布置的基础上,按照再制造生产流程的要求,分别对再制造生产过程中的拆解、清洗、检测、修复等主要工序进行设计计算,选用相应的技术方法和生产设备,并重点对生产线中的拆解、堆焊和输送部分进行研究。根据无损拆解的需要,专门设计了拆解专机。为实现生产过程的自动化,专门设计了自动堆焊专机。为满足物料输送需求,专门设计了辊子输送机。为保证差速器拆解过程的合理性和可靠性,在拆解专机的设计中,还运用了价值工程的原理和方法进行夹具的优化设计。通过功能分析,在现有拆解夹具的基础上进行结构改进,提高功能和降低成本,以更好地满足夹具在差速器拆解过程中的使用要求。
[Abstract]:The remanufacturing has great resource potential, remarkable economic benefit and obvious environmental protection function. Differential assembly is one of the important parts of construction machinery. The structure and shape of differential shell is complex, the precision is high, and the manufacture is difficult. It is one of the parts with remanufacturing value in construction machinery. Because of the evil and complexity of the working environment of construction machinery, the main parts of the differential will be worn and bumped in the process of using. It is found that the main failure form of differential housing is wear, and the wear part is on the mounting surface in contact with half-shaft gear. The shell after wear failure still has a long reserve life. It also has a feasible repair technique, which can recover the size of the worn part by surface engineering technology, and endow the new performance of the surface. Therefore, the differential shell is taken as the remanufacturing object. By using the remanufacturing technology of surfacing welding, a high efficiency and automatic production line is designed to repair the worn surface of the shell, instead of manual work, which can reduce labor intensity, improve production efficiency and realize batch production. It is undoubtedly of great practical significance to reduce production cost and promote the development of remanufacturing. Based on the analysis of the failure mode of the product, the failure characteristics of the differential housing are analyzed in this paper. The remanufacturing process of surfacing welding on the worn surface using sublaser instantaneous cold welding technology is determined. The design of the remanufacturing production line for the repair of the differential shell wear is carried out. The design is based on the process design and plane layout of the workshop in combination with the actual production. According to the requirements of the remanufacturing process, the main processes of the remanufacturing process, such as disassembly, cleaning, inspection, repair and so on, are designed and calculated, and the corresponding technical methods and production equipment are selected. In order to realize the automation of the production process, the disassembly, surfacing welding and conveying parts in the production line are studied. According to the need of non-destructive dismantling, the special disassembly machine is specially designed. The automatic surfacing welding machine is specially designed. In order to meet the requirement of material transportation, the roller conveyor is specially designed. In order to ensure the rationality and reliability of the disassembly process of the differential, the special machine is designed. The principle and method of value engineering are also used to optimize the design of the fixture. Through the function analysis, the structure of the fixture is improved on the basis of the existing disassembly of the fixture, which can improve the function and reduce the cost. In order to better meet the fixture in the differential disassembly process of the use of requirements.
【学位授予单位】：广西大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TU60

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