TJ376Q汽油机气缸体缸孔加工质量优化
摘要
本文针对天津一汽生产的TJ376Q汽油机,曾一度发生过机油耗不稳定的情况,对TJ376Q汽油机气缸体缸孔加工工艺进行分析。发动机的机油消耗直接影响着燃料经济性、动力性能、可靠性、使用寿命以及环保性能。而缸孔的加工质量,对发动机使用寿命乃至经济性、动力性有着极其重要的意义,特别是对解决发动机早磨和机油耗量高等问题起着至关重要的作用。
本文对机油耗不稳定的现象进行原因分析。找出适合TJ376Q气缸体缸孔加工质量的评定方法,并将它们当作输入(因素),将TJ376Q发动机的机油耗作为输出(实验指标),进行正交实验设计。建立TJ376Q汽油机缸孔质量与机油耗的最优方案是对于气缸体缸孔加工质量进行优化的主要环节。
Now we seek performance of engine that is high power output , low emission , low oil consumption ,compact size. Fuel consumption has influence on fuel economy , power performance ,reliability ,service life and environment protection .
Cylinder bore processing quality is important for service life of engine , economy , power performance . It is extremely effect on fuel consumption and early–wear. It is complicated for evaluating standard to processing quality of cylinder bore. Technology realization is a process of combing the product with technology . It is engine design combining the maker and machinery manufacture . So optimization of cylinder bore checker is an urgent problem for domestic engine manufacture.
There’s little argument today that a plateau cylinder bore finish provides the best surface for a new set of piston rings. A plateau finish is one that is relatively smooth and has lots of bearing area to support the rings, but also has enough crosshatch depth to retain oil and provide good ring lubrication, too.
A plateau finish essentially duplicates a broken-in cylinder. In the old days, cylinders were honed to size, and the rings did the final finishing of the bore surface. But this required a lot of break-in time and shortened the life of the rings. With today’s thin blocks, low tension piston rings, and coated pre-lapped rings, the cylinders need to be as close to a broken-in condition as possible when the engine is first fired up, otherwise the engine may use oil and never seal properly.
So what’s the best way to achieve a plateau finish? We asked a number of people in the industry and got a variety of answers. The bottom line is there is no single recipe but a number of different processes that can be used depending on the engine’s requirements and the type of honing equipment that’s being used.
This paper analyzes processing technology of cylinder bore with regard to unstable fuel consumption of TJ376Q gasoline and narrates solving methods. Evaluating methods of cylinder bore processing quality of TJ376Q cylinder body are found. Orthogonal experimental design is performed during fuel consumption acting as output data. Setting optimum plan of cylinder bore quality and fuel consumption. It is an important link for cylinder bore processing quality optimization to setting optimum plan of cylinder bore quality and fuel consumption. Introduce the technology of flat honing, research and reasoning technologic parameter of honing, particularly introduce active measure momentarily about honing. Meanwhile, the paper carried out the metrical methods to the quality of mesh veins , base on present situation of manufacture, fumble and found enterprise‘s standard of external quality about honing cylinder’s hole . Can see from being hand over an experiment result, urn the rough degree of the bore with prop up a rate to obviously influence the value that the engine oil consume.
Along with prop up a pass of rate to increase, the engine oil consumes to gradually decrease, but has already put slow trend. And in prop up the rate very highly of experiment, parts of air cylinders contain the trace that the surface grinds Sun and express to lubricate quantity shortage. Therefore prop up a rate control is the best choice in 70%-80%. Can obviously see from is hand over the experiment effect curve diagram, urn degree with rough bore to the influence that the engine oil consume very obvious, the coarseness spend low or lead the Gao all make the engine oil consume to go up, but consume the rough degree's stability in 2-3 opportune moment oils can attain the best value.
So, pass is hand over experimental methods, find out the engine oil consume of important factor, and, found out to the best process craft parameter.
The granulation and Tp of the Cylinder bore is evaluating methods of cylinder bore processing quality of TJ376Q cylinder body are found. Orthogonal experimental design is performed during fuel consumption acting as output data. Setting optimum plan of cylinder bore quality and fuel consumption. We found that granulation come up to Rz 2-3 and Tp come up to 70%-80% is the best way of low oil consumption. Technology realization is a process of combing the product with technology.
Statistical process control theory is cited. using even value-maximum difference control figure to improve the quality of products. Thus bring new & old products into hot market.
本文对机油耗不稳定的现象进行原因分析。找出适合TJ376Q气缸体缸孔加工质量的评定方法,并将它们当作输入(因素),将TJ376Q发动机的机油耗作为输出(实验指标),进行正交实验设计。建立TJ376Q汽油机缸孔质量与机油耗的最优方案是对于气缸体缸孔加工质量进行优化的主要环节。
Now we seek performance of engine that is high power output , low emission , low oil consumption ,compact size. Fuel consumption has influence on fuel economy , power performance ,reliability ,service life and environment protection .
Cylinder bore processing quality is important for service life of engine , economy , power performance . It is extremely effect on fuel consumption and early–wear. It is complicated for evaluating standard to processing quality of cylinder bore. Technology realization is a process of combing the product with technology . It is engine design combining the maker and machinery manufacture . So optimization of cylinder bore checker is an urgent problem for domestic engine manufacture.
There’s little argument today that a plateau cylinder bore finish provides the best surface for a new set of piston rings. A plateau finish is one that is relatively smooth and has lots of bearing area to support the rings, but also has enough crosshatch depth to retain oil and provide good ring lubrication, too.
A plateau finish essentially duplicates a broken-in cylinder. In the old days, cylinders were honed to size, and the rings did the final finishing of the bore surface. But this required a lot of break-in time and shortened the life of the rings. With today’s thin blocks, low tension piston rings, and coated pre-lapped rings, the cylinders need to be as close to a broken-in condition as possible when the engine is first fired up, otherwise the engine may use oil and never seal properly.
So what’s the best way to achieve a plateau finish? We asked a number of people in the industry and got a variety of answers. The bottom line is there is no single recipe but a number of different processes that can be used depending on the engine’s requirements and the type of honing equipment that’s being used.
This paper analyzes processing technology of cylinder bore with regard to unstable fuel consumption of TJ376Q gasoline and narrates solving methods. Evaluating methods of cylinder bore processing quality of TJ376Q cylinder body are found. Orthogonal experimental design is performed during fuel consumption acting as output data. Setting optimum plan of cylinder bore quality and fuel consumption. It is an important link for cylinder bore processing quality optimization to setting optimum plan of cylinder bore quality and fuel consumption. Introduce the technology of flat honing, research and reasoning technologic parameter of honing, particularly introduce active measure momentarily about honing. Meanwhile, the paper carried out the metrical methods to the quality of mesh veins , base on present situation of manufacture, fumble and found enterprise‘s standard of external quality about honing cylinder’s hole . Can see from being hand over an experiment result, urn the rough degree of the bore with prop up a rate to obviously influence the value that the engine oil consume.
Along with prop up a pass of rate to increase, the engine oil consumes to gradually decrease, but has already put slow trend. And in prop up the rate very highly of experiment, parts of air cylinders contain the trace that the surface grinds Sun and express to lubricate quantity shortage. Therefore prop up a rate control is the best choice in 70%-80%. Can obviously see from is hand over the experiment effect curve diagram, urn degree with rough bore to the influence that the engine oil consume very obvious, the coarseness spend low or lead the Gao all make the engine oil consume to go up, but consume the rough degree's stability in 2-3 opportune moment oils can attain the best value.
So, pass is hand over experimental methods, find out the engine oil consume of important factor, and, found out to the best process craft parameter.
The granulation and Tp of the Cylinder bore is evaluating methods of cylinder bore processing quality of TJ376Q cylinder body are found. Orthogonal experimental design is performed during fuel consumption acting as output data. Setting optimum plan of cylinder bore quality and fuel consumption. We found that granulation come up to Rz 2-3 and Tp come up to 70%-80% is the best way of low oil consumption. Technology realization is a process of combing the product with technology.
Statistical process control theory is cited. using even value-maximum difference control figure to improve the quality of products. Thus bring new & old products into hot market.
引文
[1] 吉林工业大学内燃机教研室,内燃机理论与设计,北京机械工业出版社,1980 年
[2] 王毓民、王恒编著,实用汽车润滑技术手册,化学工业出版社,2005 年 9月。
[3] W.H.克劳斯。汽车发动机设计,北京人民交通出版社 1986.123-15。
[4] 高国璋、赵湘杰,天津夏利、华利微型汽车发动机使用维修手册,中国物资出版社,1993。
[5] 彭庆林等,箱体加工工艺方案分析,中国机械工程学会 组合机床与自动化加工技术 2004[7]:94～98。
[6] E. Salje, et al , “Process-Optimization in honing”, Annals of the CIRP ,1987,36(1):25～29 。
[7] 张支电等,薄壁缸套工作表面的储油结构,机电工程,1999,16(6):47～48。
[8] 裘明仁译,气缸工作表面的平台珩磨(上),MTZ,1985(1):79～81。
[9] 王之其译,气缸工作表面的平台珩磨(下),MTZ,1985[3]:79～81。
[10] 周德生,平顶珩磨技术在缸孔加工中的应用,第二汽车制造厂发动机厂,1990。
[11] Flores, Gerhard, “Diamond and CBN honing technology”, Technical Paper - SME, Proceedings of the 1998 International Honing Conference, 1998(4):63～65。
[12] Horst O. Juchem, “Honing Bores With Diamond and CBN Abrasives”, Cutting Tool Engineering”, 1986(12):25～26。
[13] Shia, Ch.-Y.; Stango, R.J., “Analysis of a compliant honing toolfor brushing cylindrical surfaces”, Transactions of the ASME, 1997,8(3):98～99。
[14] Gong Y D,Li H ,Cai G Q,The Effect of Uhed Velocity and Shape on Rotating Airflow in Super-high-speed Grinding ,Key Engineering Materials,2004[259-260]:282～286.
[15] (日)樱井良文、小泉光惠编,陈俊彦译,新型陶瓷材料及其应用,中国建筑工业出版社,1983。
[16] 李子东,实用胶粘技术,新时代出版社,1998。
[17] T. Ueda, et al., “An Analytical Investigation of the Honing Mechanism”, Transactions of the ASME, 1984,8[106]:22～23。
[18] 王清明等,机械加工在线测量技术综述,计量技术,1999(4):44～46。
[19] 刘旭葵等,发动机缸孔气动在线测量系统(机械制造 2004/10)
[20] 李学媛编著,气动量仪,中国计量出版社,1998。
[21] 马以武等,厚膜微压力传感器的研究,传感器技术,1999(6):78～81。
[22] Jeff McCoy ,在机检测技术在航空发动机制造中的应用,中国机械工程学会 制造技术与机床,2005[4]:50～51。
[23] W. Koenig, F.Ferlemann, New dimension for high-speed grinding , Industrial Diamond Review, 1991[51]:546。
[24] 高凯等,发动机缸体自动测量机,中国机械工程学会 制造技术与机床,2004[10]:73～75。
[25] 谢国如等,砂带磨削技术在内孔珩磨中的应用,中国机械工程学会 组合机床与自动化加工技术,2005[1]:105～106。
[26] BARNES DRILL CO., “Vertical and horizontal honing machines”, Adv.BDH-73/GL
[27] ASM International Handbook Committee, “Metals Handbook NinthEdition”, Vol.16, METALS PARK, OH44073
[28] Kazuhiko Meakawa, Experimental Estimation for Behavior of Cylinder Oil on Cylinder Liner Surface [J], Bulletin of the JIME, 2001,29(1):62～66。
[29] 王欣玲主编,表面特征(粗糙度、波纹度、表面缺陷)国家标准应用指南,机械工业标准化技术服务部,1997 年。
[30] Wong P L、 Huang P, Effect of Geometry Change of Roughness Point Contact Due to Lubricated Sliding Wear [J], Tribology Letter ,1998,5[4]:265～274。
[31] Hans H. Fischer, “Honing Corrects Bore Errors, Improves Surface Finish”, Cutting Tool Engineering, 1986[8]:44～45。
[32] Hoffmeister, Hans-Werner; Menze, Bernd, “Process in high frequency honing”, Technical Paper - SME, 3rd International Machining and Grinding, 1999[10]:52～53。
[33] John H. Taylor, “Super-abrasive Production Honing Greater Quality, Cost Efficiency”, Cutting Tool Engineering, 1986[4]:92～93。
[34] 葛世荣、Tonder K,粗糙表面的分形特征与分形表达研究[J],摩擦学学报,1997,17(1):73～80。
[35] 张继英译,发动机气缸孔表面质量和润滑油消耗的关系,天津汽车,1996[2]:35～37。
[36] Jones & Shipman, “An INTRODUCTION To PRECISION PRODUCTION HONING”, A JONES & SHIPMAN PUBLICATION, No.423
[37] Keh Tung Satistical Process Control . 美国质量控制协会. 1997(1):65～68。
[38] TJ376QE 系列汽油机机体缸孔表面平台珩磨网纹技术规范及检测方法,天津市内燃机厂,1996[3]。
[39] 祝锡晶等,提高发动机缸套表面质量的新工艺,中国内燃机学会 内燃机工程,2003[4]:66～73。
[40] Klink, Ulrich; Flores, Gerhard, “New technologies of honing”, Technical Paper - SME, Proceedings of the 1998 International Honing Conference, 1998[8]:32～35。
[41] K. Yokoyama, et al., “Analysis of Dimensional Error and Improvement of Honing Accuracy by In-process Compensation of Thermal and Elastic Deformation”, Int. J. Soc. Prec. Eng., 1992,26[3]:121～122。
[2] 王毓民、王恒编著,实用汽车润滑技术手册,化学工业出版社,2005 年 9月。
[3] W.H.克劳斯。汽车发动机设计,北京人民交通出版社 1986.123-15。
[4] 高国璋、赵湘杰,天津夏利、华利微型汽车发动机使用维修手册,中国物资出版社,1993。
[5] 彭庆林等,箱体加工工艺方案分析,中国机械工程学会 组合机床与自动化加工技术 2004[7]:94～98。
[6] E. Salje, et al , “Process-Optimization in honing”, Annals of the CIRP ,1987,36(1):25～29 。
[7] 张支电等,薄壁缸套工作表面的储油结构,机电工程,1999,16(6):47～48。
[8] 裘明仁译,气缸工作表面的平台珩磨(上),MTZ,1985(1):79～81。
[9] 王之其译,气缸工作表面的平台珩磨(下),MTZ,1985[3]:79～81。
[10] 周德生,平顶珩磨技术在缸孔加工中的应用,第二汽车制造厂发动机厂,1990。
[11] Flores, Gerhard, “Diamond and CBN honing technology”, Technical Paper - SME, Proceedings of the 1998 International Honing Conference, 1998(4):63～65。
[12] Horst O. Juchem, “Honing Bores With Diamond and CBN Abrasives”, Cutting Tool Engineering”, 1986(12):25～26。
[13] Shia, Ch.-Y.; Stango, R.J., “Analysis of a compliant honing toolfor brushing cylindrical surfaces”, Transactions of the ASME, 1997,8(3):98～99。
[14] Gong Y D,Li H ,Cai G Q,The Effect of Uhed Velocity and Shape on Rotating Airflow in Super-high-speed Grinding ,Key Engineering Materials,2004[259-260]:282～286.
[15] (日)樱井良文、小泉光惠编,陈俊彦译,新型陶瓷材料及其应用,中国建筑工业出版社,1983。
[16] 李子东,实用胶粘技术,新时代出版社,1998。
[17] T. Ueda, et al., “An Analytical Investigation of the Honing Mechanism”, Transactions of the ASME, 1984,8[106]:22～23。
[18] 王清明等,机械加工在线测量技术综述,计量技术,1999(4):44～46。
[19] 刘旭葵等,发动机缸孔气动在线测量系统(机械制造 2004/10)
[20] 李学媛编著,气动量仪,中国计量出版社,1998。
[21] 马以武等,厚膜微压力传感器的研究,传感器技术,1999(6):78～81。
[22] Jeff McCoy ,在机检测技术在航空发动机制造中的应用,中国机械工程学会 制造技术与机床,2005[4]:50～51。
[23] W. Koenig, F.Ferlemann, New dimension for high-speed grinding , Industrial Diamond Review, 1991[51]:546。
[24] 高凯等,发动机缸体自动测量机,中国机械工程学会 制造技术与机床,2004[10]:73～75。
[25] 谢国如等,砂带磨削技术在内孔珩磨中的应用,中国机械工程学会 组合机床与自动化加工技术,2005[1]:105～106。
[26] BARNES DRILL CO., “Vertical and horizontal honing machines”, Adv.BDH-73/GL
[27] ASM International Handbook Committee, “Metals Handbook NinthEdition”, Vol.16, METALS PARK, OH44073
[28] Kazuhiko Meakawa, Experimental Estimation for Behavior of Cylinder Oil on Cylinder Liner Surface [J], Bulletin of the JIME, 2001,29(1):62～66。
[29] 王欣玲主编,表面特征(粗糙度、波纹度、表面缺陷)国家标准应用指南,机械工业标准化技术服务部,1997 年。
[30] Wong P L、 Huang P, Effect of Geometry Change of Roughness Point Contact Due to Lubricated Sliding Wear [J], Tribology Letter ,1998,5[4]:265～274。
[31] Hans H. Fischer, “Honing Corrects Bore Errors, Improves Surface Finish”, Cutting Tool Engineering, 1986[8]:44～45。
[32] Hoffmeister, Hans-Werner; Menze, Bernd, “Process in high frequency honing”, Technical Paper - SME, 3rd International Machining and Grinding, 1999[10]:52～53。
[33] John H. Taylor, “Super-abrasive Production Honing Greater Quality, Cost Efficiency”, Cutting Tool Engineering, 1986[4]:92～93。
[34] 葛世荣、Tonder K,粗糙表面的分形特征与分形表达研究[J],摩擦学学报,1997,17(1):73～80。
[35] 张继英译,发动机气缸孔表面质量和润滑油消耗的关系,天津汽车,1996[2]:35～37。
[36] Jones & Shipman, “An INTRODUCTION To PRECISION PRODUCTION HONING”, A JONES & SHIPMAN PUBLICATION, No.423
[37] Keh Tung Satistical Process Control . 美国质量控制协会. 1997(1):65～68。
[38] TJ376QE 系列汽油机机体缸孔表面平台珩磨网纹技术规范及检测方法,天津市内燃机厂,1996[3]。
[39] 祝锡晶等,提高发动机缸套表面质量的新工艺,中国内燃机学会 内燃机工程,2003[4]:66～73。
[40] Klink, Ulrich; Flores, Gerhard, “New technologies of honing”, Technical Paper - SME, Proceedings of the 1998 International Honing Conference, 1998[8]:32～35。
[41] K. Yokoyama, et al., “Analysis of Dimensional Error and Improvement of Honing Accuracy by In-process Compensation of Thermal and Elastic Deformation”, Int. J. Soc. Prec. Eng., 1992,26[3]:121～122。