曲轴加工工艺及曲轴内铣技术的研究
摘要
近年来,随汽车工业的蓬勃发展,国内对汽车用柴油机、汽油机的需求量不断上升,对其质量的要求也不断提高。曲轴是柴油、汽油发动机中的一个关键零件,起着传递动力的作用,工作中承受复杂的交变载荷,主要失效形式是圆角处的疲劳断裂,曲轴的质量直接影响发动机的动力性能,也影响整机的使用寿命。
曲轴内铣技术是一种先进的曲轴加工技术,用于主轴颈、连杆轴颈的粗加工,亦可同时用于圆角和曲柄臂侧面的加工。对于汽车发动机用锻钢曲轴,内铣加工容易断屑,加工余量大,对毛坯质量要求低,比较适应国内曲轴毛坯的生产现状,被多家发动机生产厂所采用。
有限元法随着计算机技术的发展,已经在很多工程领域中得到了广泛的运用。发动机零部件的研发、设计也大量使用有限元方法进行分析,这使零部件的可靠性得到了提高,设计周期得到了缩短,给设计者带来很大方便。
本文以ZJ25型曲轴为研究对象,对其加工工艺进行了分析,并着重对打中心孔、磨削、强化等工序进行了研究,找出了工艺中存在的一些问题,做出了工艺水平评价。
文章还对曲轴内铣技术做了重点研究,将内铣工艺与其它曲轴轴颈粗加工工艺进行了比较分析,对内铣加工原理、内铣加工设备进行了研究,还对曲轴连杆轴颈及圆角处进行了受力分析,发现了经内铣加工后轴颈圆角处存在的应力集中问题。
针对ZJ25型曲轴的连杆轴颈,设计了三种不同形状、尺寸的圆角,并建立了三种连杆轴颈的几何模型,在ANSYS软件中对其划分网格,施加约束条件及载荷,求解。对计算结果进行分析,找出了最适合内铣加工工艺,最大应力较小的一种圆角设计方案,提高了内铣加工质量,改善了圆角应力集中现象。
With the fast development of automobile industry recently, the native demands of diesel engine and gasoline engine are rising constantly while the quality requirements are continuously heightened. Crankshaft which acts as a power-transfer medium is the key component of diesel engine and gasoline engine and it endures complexity alternating load. The main failure mode is the fatigue fracture in fillets. The quality of crankshaft directly affects the dynamic performance and the service life of engine.
The inner milling of crankshaft as an advanced technology is not only applied to the rough machining of the main journal and rod journal, but also used in the machining of the milling fillets and the crank arm side. The inner milling, which is used to forge steel crankshaft in automobile engine, has been adapted to the domestic crankshaft blank production status and used by many engine factories, because of its easy broken chip, large machining redundancy and low requirement of quality roughcast.
Along with the development of the computer technology the finite element method (FEM) has been widely applied in many engineering fields. It has also been applied to the designing and developing of automobile engine accessory. FEM brings a lot of convenience to the designers,because it improves the reliability of accessory and shortens the design cycle.
This article analyses the processing technology of crankshaft ZJ25, especially the working procedures of drilling the central hole, grinding and strengthening. Some problems in processing have been found out and an evaluation for processing technical level has been made.
This article also emphatically studies the technology of the inner milling of crankshaft. By means of comparing the inner milling processing with the other rough machining processing for the crankshaft journal, the inner milling machining principle and machining equipment are studied. Through the force analysis of fillets and rod journal, the stress concentration problem of the journal fillets after the inner milling are found out.
Three kinds of fillets with different shape or size for the rod journal of ZJ25 crankshaft have been designed. It establishes three kinds of geometric models for the rod journal, meshing and defining the boundary conditions and applying stress, and solving with the ANSYS software. By analyzing the results, a fillets design scheme with the most suitable inner milling processing technology and the less maximum stress is obtained. It increases the processing quality of inner milling and improves the stress concentration of fillets.
曲轴内铣技术是一种先进的曲轴加工技术,用于主轴颈、连杆轴颈的粗加工,亦可同时用于圆角和曲柄臂侧面的加工。对于汽车发动机用锻钢曲轴,内铣加工容易断屑,加工余量大,对毛坯质量要求低,比较适应国内曲轴毛坯的生产现状,被多家发动机生产厂所采用。
有限元法随着计算机技术的发展,已经在很多工程领域中得到了广泛的运用。发动机零部件的研发、设计也大量使用有限元方法进行分析,这使零部件的可靠性得到了提高,设计周期得到了缩短,给设计者带来很大方便。
本文以ZJ25型曲轴为研究对象,对其加工工艺进行了分析,并着重对打中心孔、磨削、强化等工序进行了研究,找出了工艺中存在的一些问题,做出了工艺水平评价。
文章还对曲轴内铣技术做了重点研究,将内铣工艺与其它曲轴轴颈粗加工工艺进行了比较分析,对内铣加工原理、内铣加工设备进行了研究,还对曲轴连杆轴颈及圆角处进行了受力分析,发现了经内铣加工后轴颈圆角处存在的应力集中问题。
针对ZJ25型曲轴的连杆轴颈,设计了三种不同形状、尺寸的圆角,并建立了三种连杆轴颈的几何模型,在ANSYS软件中对其划分网格,施加约束条件及载荷,求解。对计算结果进行分析,找出了最适合内铣加工工艺,最大应力较小的一种圆角设计方案,提高了内铣加工质量,改善了圆角应力集中现象。
With the fast development of automobile industry recently, the native demands of diesel engine and gasoline engine are rising constantly while the quality requirements are continuously heightened. Crankshaft which acts as a power-transfer medium is the key component of diesel engine and gasoline engine and it endures complexity alternating load. The main failure mode is the fatigue fracture in fillets. The quality of crankshaft directly affects the dynamic performance and the service life of engine.
The inner milling of crankshaft as an advanced technology is not only applied to the rough machining of the main journal and rod journal, but also used in the machining of the milling fillets and the crank arm side. The inner milling, which is used to forge steel crankshaft in automobile engine, has been adapted to the domestic crankshaft blank production status and used by many engine factories, because of its easy broken chip, large machining redundancy and low requirement of quality roughcast.
Along with the development of the computer technology the finite element method (FEM) has been widely applied in many engineering fields. It has also been applied to the designing and developing of automobile engine accessory. FEM brings a lot of convenience to the designers,because it improves the reliability of accessory and shortens the design cycle.
This article analyses the processing technology of crankshaft ZJ25, especially the working procedures of drilling the central hole, grinding and strengthening. Some problems in processing have been found out and an evaluation for processing technical level has been made.
This article also emphatically studies the technology of the inner milling of crankshaft. By means of comparing the inner milling processing with the other rough machining processing for the crankshaft journal, the inner milling machining principle and machining equipment are studied. Through the force analysis of fillets and rod journal, the stress concentration problem of the journal fillets after the inner milling are found out.
Three kinds of fillets with different shape or size for the rod journal of ZJ25 crankshaft have been designed. It establishes three kinds of geometric models for the rod journal, meshing and defining the boundary conditions and applying stress, and solving with the ANSYS software. By analyzing the results, a fillets design scheme with the most suitable inner milling processing technology and the less maximum stress is obtained. It increases the processing quality of inner milling and improves the stress concentration of fillets.
引文
[1]李秋伟.对我国汽车发展现状及其对策的分析.消费导刊,2007(11):240
[2]倪计民编著.汽车内燃机原理.上海:同济大学出版社,1997:12-35
[3]彭丽华.内燃机曲轴制造技术新论.金属成形工艺,2004,22:15-18
[4]屈贤明.装备制造业的振兴和产品创新.中国机械工程,2002(4):282-284
[5]王晓兰.我国发动机曲轴制造的发展趋势.内江科技,2007,8:140
[6]王一治.国内外曲轴制造工艺综述.山东农机,2001,5:22-23
[7] Daris P C,Gomez M P.etal.Arational analytic theory of fatigue.Trend in Engineering,1961,113:9-4
[8]韩爱礼.曲轴铣削加工工艺现状及设备.内燃机,1999,5:15-18
[9]李海国,张小菊.发动机曲轴高效加工技术的应用与进展.机械工人,2007,5:32-34
[10] Maason S S.Fatigue a complex Subjeet-some simple approximations.Experimental Mechanics,1965,5
[11] Paris P C,Erdugam F.Critical analysis of crsck propagation Lows.Ttans,ASME.J.Basic Eng,1963,85:528-534
[12] J.Donea.A Taylor-Galerlkin Methods for Convective Tmnsport Problems.Int,J Numer Methods Eng, 1984,20(1):109-119
[13]蒋孝煜.有限元法基础.北京:清华大学出版社,1992:32-56
[14]张延青编著.ANSYS和Matlab有限元分析.北京:清华大学出版社,2002:8-46
[15]康贵信,邹家祥编著.有限元法及其在冶金机械中的应用.北京:冶金工业出版社,1991:1-82
[16]程道广.采用低温淬火的方法改善42CrMo钢的切削性能.热处理技术与装备,2007,4(2):42-43
[17]赵绪国.42CrMo曲轴坯的工艺改进.机械工程与自动化,2007,8(4):167-168
[18]顾永生编著.现代轿车先进制造工艺.上海:上海交通大学出版社,1998:21 -32
[19]周龙保编著.内燃机学.北京:机械工业出版社,2000: 2-66
[20]李绍明编著.机械加工工艺基础.北京:北京理工大学出版社,1993:5-71
[21]李玉森.六缸柴油机曲轴机械制造工艺研究及应用:[学位论文].天津:天津大学,2003(4)
[22]王仲.曲轴粗加工关键工艺及设备的比较.内燃机,2003,1:23-28
[23]汤晓宇.汽车发动机曲轴机加工技术.汽车工艺与材料,2007(6):35-36
[24]齐忠华,刘殿友,赵铁岩.曲轴的内铣和车拉柔性机床.机械设计与制造,1999(1):51
[25]鄢国洪,时洪洲.曲轴内铣刀片的国产化.工具技术, 2000,35:30-31
[26]杜静编著.机械CAD/CAE应用技术基础.北京:机械工业出版社,2002:3-58
[27]张立新,徐长航等编著.ANSYS7.0基础教程.北京:机械工业出版社,2004:1-47
[28]刘国庆,杨庆东.ANSYS工程应用教程机械篇.北京:中国铁道出版社,2003:1-86
[29]龚曙光.ANSYS工程应用实例解析.北京:机械土业出版社,2003(4):1-42
[30]西田正孝著,李安定等译.应力集中.北京:机械工业出版社,1986:93-119
[31]航空工业部科学技术委员会.应力集中系数手册.北京:高等教育出版社,1990:1-41
[32]董玉集.CAD中若干接口问题的研究.计算机辅助设计与制造,2002(l):74-77
[33]谭建国.使用ANSYS6.0进行有限元分析.北京:北京大学出版社,2002(5):394-342
[34]张汝情,詹先义编著.非线性有限元分析.重庆:重庆大学出版社,1990: 2-76
[35]徐颧.机械设计师手册.北京:机械工业出版社,1995(3):255-271
[36]苏海峰.基于ANSYS软件的柴油机曲轴有限元分析.内燃机配件,2007(2):18-20
[37]周志鸿,李晓,孙常盛.基于ANSYS的曲柄压力机曲轴刚度分析.锻压技术,2007(10):114-117
[38]孙连科,唐斌,薛冬新,宋希庚.6110柴油机曲轴的三维有限元分析.车用发动机,2007(4):81-84
[39] Zienkiewicz O C, Taylor R L.The Finite Element Method.Butterworth-Heinemann, 2000
[40] Thomas J R . The Finite element method : linear static and dynamic finite element analysis.Prentice-Hall,1987
[2]倪计民编著.汽车内燃机原理.上海:同济大学出版社,1997:12-35
[3]彭丽华.内燃机曲轴制造技术新论.金属成形工艺,2004,22:15-18
[4]屈贤明.装备制造业的振兴和产品创新.中国机械工程,2002(4):282-284
[5]王晓兰.我国发动机曲轴制造的发展趋势.内江科技,2007,8:140
[6]王一治.国内外曲轴制造工艺综述.山东农机,2001,5:22-23
[7] Daris P C,Gomez M P.etal.Arational analytic theory of fatigue.Trend in Engineering,1961,113:9-4
[8]韩爱礼.曲轴铣削加工工艺现状及设备.内燃机,1999,5:15-18
[9]李海国,张小菊.发动机曲轴高效加工技术的应用与进展.机械工人,2007,5:32-34
[10] Maason S S.Fatigue a complex Subjeet-some simple approximations.Experimental Mechanics,1965,5
[11] Paris P C,Erdugam F.Critical analysis of crsck propagation Lows.Ttans,ASME.J.Basic Eng,1963,85:528-534
[12] J.Donea.A Taylor-Galerlkin Methods for Convective Tmnsport Problems.Int,J Numer Methods Eng, 1984,20(1):109-119
[13]蒋孝煜.有限元法基础.北京:清华大学出版社,1992:32-56
[14]张延青编著.ANSYS和Matlab有限元分析.北京:清华大学出版社,2002:8-46
[15]康贵信,邹家祥编著.有限元法及其在冶金机械中的应用.北京:冶金工业出版社,1991:1-82
[16]程道广.采用低温淬火的方法改善42CrMo钢的切削性能.热处理技术与装备,2007,4(2):42-43
[17]赵绪国.42CrMo曲轴坯的工艺改进.机械工程与自动化,2007,8(4):167-168
[18]顾永生编著.现代轿车先进制造工艺.上海:上海交通大学出版社,1998:21 -32
[19]周龙保编著.内燃机学.北京:机械工业出版社,2000: 2-66
[20]李绍明编著.机械加工工艺基础.北京:北京理工大学出版社,1993:5-71
[21]李玉森.六缸柴油机曲轴机械制造工艺研究及应用:[学位论文].天津:天津大学,2003(4)
[22]王仲.曲轴粗加工关键工艺及设备的比较.内燃机,2003,1:23-28
[23]汤晓宇.汽车发动机曲轴机加工技术.汽车工艺与材料,2007(6):35-36
[24]齐忠华,刘殿友,赵铁岩.曲轴的内铣和车拉柔性机床.机械设计与制造,1999(1):51
[25]鄢国洪,时洪洲.曲轴内铣刀片的国产化.工具技术, 2000,35:30-31
[26]杜静编著.机械CAD/CAE应用技术基础.北京:机械工业出版社,2002:3-58
[27]张立新,徐长航等编著.ANSYS7.0基础教程.北京:机械工业出版社,2004:1-47
[28]刘国庆,杨庆东.ANSYS工程应用教程机械篇.北京:中国铁道出版社,2003:1-86
[29]龚曙光.ANSYS工程应用实例解析.北京:机械土业出版社,2003(4):1-42
[30]西田正孝著,李安定等译.应力集中.北京:机械工业出版社,1986:93-119
[31]航空工业部科学技术委员会.应力集中系数手册.北京:高等教育出版社,1990:1-41
[32]董玉集.CAD中若干接口问题的研究.计算机辅助设计与制造,2002(l):74-77
[33]谭建国.使用ANSYS6.0进行有限元分析.北京:北京大学出版社,2002(5):394-342
[34]张汝情,詹先义编著.非线性有限元分析.重庆:重庆大学出版社,1990: 2-76
[35]徐颧.机械设计师手册.北京:机械工业出版社,1995(3):255-271
[36]苏海峰.基于ANSYS软件的柴油机曲轴有限元分析.内燃机配件,2007(2):18-20
[37]周志鸿,李晓,孙常盛.基于ANSYS的曲柄压力机曲轴刚度分析.锻压技术,2007(10):114-117
[38]孙连科,唐斌,薛冬新,宋希庚.6110柴油机曲轴的三维有限元分析.车用发动机,2007(4):81-84
[39] Zienkiewicz O C, Taylor R L.The Finite Element Method.Butterworth-Heinemann, 2000
[40] Thomas J R . The Finite element method : linear static and dynamic finite element analysis.Prentice-Hall,1987