某发动机缸体曲轴孔激光涨断加工工艺及质量控制研究
发布时间：2018-08-30 14:13
【摘要】：缸体曲轴孔是发动机中的重要结构,大多数国内发动机生产厂家仍然采用传统分体式加工方法加工缸体曲轴孔,这种方法需要单独铸造、加工缸体、曲轴箱两个部件,工艺复杂,加工成本高,曲轴孔合箱定位精度较差,并且发动机性能及使用寿命受到限制。与传统分体式加工工艺相比,激光涨断工艺的工艺路线简单,可以大量缩减加工工序、减少加工设备用量,并且曲轴孔座与瓦盖定位精度、装配质量大幅提高,极大提升了曲轴孔合箱后的承载、抗剪切能力,对提高发动机整机性能具有重要作用。另外涨断技术可以减少机加工序60%,节省机床设备投资25%,减少刀具费用35%,节省能源40%,还可以减少占地面积、减少废品率等,经济效益可观。因此发动机缸体曲轴孔涨断加工是大势所趋,但目前国内的涨断加工工艺水平并不成熟,实际生产中还存在撕裂、裂不开、掉渣、断裂面变形等涨断缺陷,影响产品质量稳定性。鉴于上述原因,本课题以某工厂MC系列大功率发动机的蠕墨铸铁材料缸体作为研究对象,研究缸体曲轴孔激光涨断加工工艺,对ALFING激光涨断设备进行介绍和分析,并对实际生产过程中遇到的质量问题进行深入分析和追踪。主要内容包括:(1)对MC系列发动机缸体蠕墨铸铁材料的成分特点及力学性能进行了基本介绍,对曲轴孔分离加工用的ALFING激光涨断设备的构建,曲轴孔涨断的工艺特点、技术要求和典型缺陷进行了初步介绍。(2)介绍了ALFING设备高能激光的产生过程,详细阐述了激光的产生及控制的原理,对本课题采用的某工厂激光刻痕设备进行了系统说明,并结合该设备阐述了激光刻痕实现的方法及过程,同时阐述了激光脉冲参数对于涨断槽影响。(3)研究曲轴孔涨断实际生产过程中遇到的质量问题,以曲轴孔涨断后掉渣比率过高问题为切入点,对导致涨断面掉渣的因素通过六西格玛质量改进工具进行分析、优化的过程进行了详细介绍。通过头脑风暴法、利用鱼骨图工具、DOE实验方法等,识别出导致曲轴孔涨断面掉渣的关键影响因素,并对其进行改善。并对改善后的质量状态、经济效益进行了跟踪确认。本文研究、分析了大功率发动机蠕墨铸铁材料缸体,在利用激光涨断技术进行曲轴孔的分离加工过程中出现的典型问题,对某工厂MC系列发动机提升产品质量、保障产品在国内乃至世界的领先地位,有着重要作用,同时对于国内的激光涨断技术研究及同类发动机缸体曲轴孔的加工制造及质量控制具有一定的参考意义。
[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.
【学位授予单位】：江苏大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TK403;TN249
本文编号：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.
【学位授予单位】：江苏大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TK403;TN249
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