新一代内燃机超精密偶件加工技术研究
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摘要
随着环境污染的日益严重,保护环境已成为二十一世纪社会发展的主题。从2000年开始,我国政府开始实施新的排放标准,我国原有的系列燃油喷射系统,技术含量低,工作能力小,不能满足新的排放法规和市场的要求。由天津大学内燃机重点实验室研制的新一代内燃机平衡阀偶件,既能满足新的排放法规的要求,又能满足国内柴油机的装机要求,适应了目前柴油机向大功率增压中冷的发展趋势,经济性能良好,适合己经实施的排放法规。在今后的两三年内,新一代内燃机平衡阀偶件将在内燃机行业中得到广泛的应用,而平衡阀偶件的大批量稳定性生产也就成了至关重要的问题。
本文在借鉴国内外柱塞偶件加工工艺的基础上,对平衡阀偶件结构及其工艺难点进行了分析,制定了平衡阀偶件大批量生产加工工艺流程,并根据现有生产条件加工平衡阀偶件试验样件,对其中出现的问题进行分析解决。提出了精密柱塞副偶件调整法加工的尺寸偶配统计学原理,给出了偶件配合间隙形成条件、偶配间隙与配偶尺寸统计特征的关系,为偶件的分选偶配及面向分选配对的调整法偶件加工提供统计学理论依据,为实现偶件加工统计过程控制和6σ偶配打下基础。根据偶件加工统计过程控制(Statistical Process Control,SPC)理论,编程开发了平衡阀偶件SPC质量监测系统。对珩磨精密加工工艺进行了实验研究,分析了粗珩加工中网纹角、工作压力、珩磨速度与材料去除率的关系。
Environmental protection has become a main topic of social development of 21th century along with increasingly severe pollution of the environment. And the new emission control regulation has come into force in our country since 2000. Original fuel injection system series with low technology and capacity made in our country can not meet the new emission control regulation as well as the market demands. The balancing valve couples of new generation internal combustion engine developed by the State Key Laboratory of engine of Tianjin University can meet not only the demands of the new emission control regulation but also the demands of domestic diesel engines. Therefore it is suitable for the developing trend of the diesel engine for high power and intercooling with good economy. In the coming two or three years, the balancing valve couples of new generation internal combustion engine is becoming widespread use in the industy of internal combustion engine. Therefore it is important to volume-produce the balancing valve couples used for internal combustion engine.
Based on the machining technology for plunger couples at home and abroad, the present work aims to lay down process flow for balancing valve couples and to machine experimental samples according to present manufacture condition. Considering the manufacturing state-of-arts of precision plunger pair couple, statistics principle for dimension matching of precision plunger pair couple was proposed in this paper. Condition of dimension matching, relationships among the statistical characteristics of matching clearance and dimensions were put forward to provide a statistics theoretical basis for the grouping pairing method and regulated machining based on it and, above all, to lay a foundation for the statistical process control of couples machining and 6-σgrouping pairing. SPC quality monitor system for balancing vlave couples are programmed according to the theory of statistical process for couples machining. Honing experiments are executed and the relationships between reticulate cross-angle, honing pressure, honing rates and material removal rate are analyzed in rough honing。
本文在借鉴国内外柱塞偶件加工工艺的基础上,对平衡阀偶件结构及其工艺难点进行了分析,制定了平衡阀偶件大批量生产加工工艺流程,并根据现有生产条件加工平衡阀偶件试验样件,对其中出现的问题进行分析解决。提出了精密柱塞副偶件调整法加工的尺寸偶配统计学原理,给出了偶件配合间隙形成条件、偶配间隙与配偶尺寸统计特征的关系,为偶件的分选偶配及面向分选配对的调整法偶件加工提供统计学理论依据,为实现偶件加工统计过程控制和6σ偶配打下基础。根据偶件加工统计过程控制(Statistical Process Control,SPC)理论,编程开发了平衡阀偶件SPC质量监测系统。对珩磨精密加工工艺进行了实验研究,分析了粗珩加工中网纹角、工作压力、珩磨速度与材料去除率的关系。
Environmental protection has become a main topic of social development of 21th century along with increasingly severe pollution of the environment. And the new emission control regulation has come into force in our country since 2000. Original fuel injection system series with low technology and capacity made in our country can not meet the new emission control regulation as well as the market demands. The balancing valve couples of new generation internal combustion engine developed by the State Key Laboratory of engine of Tianjin University can meet not only the demands of the new emission control regulation but also the demands of domestic diesel engines. Therefore it is suitable for the developing trend of the diesel engine for high power and intercooling with good economy. In the coming two or three years, the balancing valve couples of new generation internal combustion engine is becoming widespread use in the industy of internal combustion engine. Therefore it is important to volume-produce the balancing valve couples used for internal combustion engine.
Based on the machining technology for plunger couples at home and abroad, the present work aims to lay down process flow for balancing valve couples and to machine experimental samples according to present manufacture condition. Considering the manufacturing state-of-arts of precision plunger pair couple, statistics principle for dimension matching of precision plunger pair couple was proposed in this paper. Condition of dimension matching, relationships among the statistical characteristics of matching clearance and dimensions were put forward to provide a statistics theoretical basis for the grouping pairing method and regulated machining based on it and, above all, to lay a foundation for the statistical process control of couples machining and 6-σgrouping pairing. SPC quality monitor system for balancing vlave couples are programmed according to the theory of statistical process for couples machining. Honing experiments are executed and the relationships between reticulate cross-angle, honing pressure, honing rates and material removal rate are analyzed in rough honing。
引文
[1] 上海市机电一局情报站, 国外柴油机油泵油嘴行业生产情况综述, 1975
[2] Η.И. 巴赫齐罗夫,В.Е. 洛吉诺夫著 黄启良译,柴油机精密偶件的生产与使用[M],国防工业出版社,北京,1984:92
[3] 农业机械部第二设计研究院, 油泵油嘴制造技术, 一机部科学技术情报研究所, 1981.5
[4] 谢祖林, 喷油嘴偶件加工工艺探讨, 现代车用电力, 2002.8
[5] 蔡志兵, 珩磨工艺在柱塞套中孔精加工中的应用, 油泵油嘴技术 1994.4
[6] 傅平响, 张红燕, 袁海章, 毛小平, 采用配磨工艺柱塞偶件的试验研究[J], 内燃机燃油喷射和控制, 2001(4):14~22
[7] 徐之光, 提高偶件研磨质量的实践, 油泵油嘴技术, 1994.1
[8] 俞年荣, 配磨技术简介, 内燃机燃油喷射和控制, 1996.2
[9] 许凯明, 喷油泵柱塞偶件配磨技术和检验方法的研究, 内燃机燃油喷射和控制, 1998.4
[10] 史祥增, 柱塞偶件加工工艺探讨, 油泵油嘴技术, 1995.3
[11] 黄维强, 卧式珩磨机在偶见生产中的应用, 内燃机燃油喷射和控制, 1999.1
[12] [俄] 柱塞偶件自动配副的工艺保证, 内燃机燃油喷射和控制, 1999.2
[13] 赵明生, 机械工程师手册, 机械工业出版社, 2006.2
[14] VENTEC 英国深孔钻系统操作说明书(中文版)
[15] 毛小平, 采用配磨工艺柱塞偶件的试验研究, 内燃机燃油喷射和控制, 2001.4
[16] 王世清, 孔加工技术, 石油工业出版社, 1993
[17] 朱祖良, 孔加工刀具, 国防工业出版社, 1980.1
[18] [美]霍尔登 J.斯温哈特, 深孔加工, 国防工业出版社, 1974.12
[19] 王伟方, 实现柱塞中孔以珩代磨及珩磨技术的发展, 内燃机燃油喷射和控制,1995.1 [20」蔡向东, 外排屑深孔钻工艺参数的选择, 机械工艺师, 2000.12
[21] 孟少农, 机械加工工艺手册, 机械工业出版社, 1991
[22] 倪南良, 小孔卧式珩磨工艺余量分析, 内燃机燃油喷射和控制, 1996.4 [23〕方刚,曾攀,切削加工过程数值模拟的研究进展,力学进展,2001,31(3):394～403
[24] 李立, 珩磨原理与实践, 天津大学出版社, 1995.6
[25] 杨立, 连杆珩磨质量攻关, 天津内燃机厂论文集, 1999
[26] 何英, 表面粗糙度检测, 中国计量出版社, 1998.5
[27] 王欣玲, 表面特征国家标准应用指南, 机械工业标准化技术服务部 1997
[28] Klink,Urich;Flores,Gerhard, New technologies of honing Technical Paper-SME, Proceedings of the 1998 International Honing Conference, Apr,1998
[29] Flores,Gehard, Diamond and CBN honing technology Technical Paper-SME, Proceedings of the 1998 International Honing Conference, Apr,1998
[30] Horest O.Juchem, Honing Bores With Diamond and CBN Abrasives Cutting Tool Engineering, Dec,1986
[31] Hans H. Fischer, Honing Corrects Bore Errors, Improves Surface Finish Cutting Tool Engineering, Aug,1986
[32] E.Salje,et al, Process-Optimization in honing, CIRP Annals Vol 36,No.1,1987
[33] 章渭基, 质量控制, 科学出版社, 1988
[34] 徐扬光, 质量管理的数理统计方法, 1985
[35] 张丽敏, 柱塞偶件配磨技术与检验方法的研究, 内燃机燃油喷射和控制, 2001.1
[36] 马行, 柱塞套中孔直线度质量控制探讨, 油泵油嘴技术, 1995.1
[37] MBC-1805, 珩磨机随机用户手册
[38] 陈松川, P7 系列柱塞套中孔纯珩磨工艺, 现代车用动力, 2003.2
[39] 李良福, 加工精密孔的各种方法, 工艺与装备, 2003
[40] [日]田中义信, 精密加工法, 机械工业出版社, 1993.10
[41] 严克治, 精密微小孔电火花加工实验装置设计及实验, 南京航空学院学报, 1991.9
[42] 何家秉, 整体硬质台金枪钻在特深小孔钻削中的应用, 工具技术, 1992.10
[43] 杨逸群, 柱塞套中孔加工及装备改进的探讨, 油泵油嘴技术, 1995.1
[44] 华韬,,喷油泵柱塞偶件径部密封试验方法及参数的确定, 内燃机燃油喷射和控制, 1999,2
[45] 吴方, 李少锋, 许明凯, 喷油泵柱塞偶件配磨技术的研究[J],现代车用动力,2002(2):32~33
[46] 张丽敏,柱塞偶件配磨技术与检验方法的研究[J],内燃机燃油喷射和控制,2001(1):33~35
[47] 王琬山, 邢敏主编,机械制造手册[M],辽宁科学技术出版社,2002:499
[48] 徐宁, 精密加工技术的现状及发展前景, 机械制造 41 卷, 第 469 期
[49] 李隆章编著,质量管理中的统计方法[M],上海人民出版社 1987:4
[2] Η.И. 巴赫齐罗夫,В.Е. 洛吉诺夫著 黄启良译,柴油机精密偶件的生产与使用[M],国防工业出版社,北京,1984:92
[3] 农业机械部第二设计研究院, 油泵油嘴制造技术, 一机部科学技术情报研究所, 1981.5
[4] 谢祖林, 喷油嘴偶件加工工艺探讨, 现代车用电力, 2002.8
[5] 蔡志兵, 珩磨工艺在柱塞套中孔精加工中的应用, 油泵油嘴技术 1994.4
[6] 傅平响, 张红燕, 袁海章, 毛小平, 采用配磨工艺柱塞偶件的试验研究[J], 内燃机燃油喷射和控制, 2001(4):14~22
[7] 徐之光, 提高偶件研磨质量的实践, 油泵油嘴技术, 1994.1
[8] 俞年荣, 配磨技术简介, 内燃机燃油喷射和控制, 1996.2
[9] 许凯明, 喷油泵柱塞偶件配磨技术和检验方法的研究, 内燃机燃油喷射和控制, 1998.4
[10] 史祥增, 柱塞偶件加工工艺探讨, 油泵油嘴技术, 1995.3
[11] 黄维强, 卧式珩磨机在偶见生产中的应用, 内燃机燃油喷射和控制, 1999.1
[12] [俄] 柱塞偶件自动配副的工艺保证, 内燃机燃油喷射和控制, 1999.2
[13] 赵明生, 机械工程师手册, 机械工业出版社, 2006.2
[14] VENTEC 英国深孔钻系统操作说明书(中文版)
[15] 毛小平, 采用配磨工艺柱塞偶件的试验研究, 内燃机燃油喷射和控制, 2001.4
[16] 王世清, 孔加工技术, 石油工业出版社, 1993
[17] 朱祖良, 孔加工刀具, 国防工业出版社, 1980.1
[18] [美]霍尔登 J.斯温哈特, 深孔加工, 国防工业出版社, 1974.12
[19] 王伟方, 实现柱塞中孔以珩代磨及珩磨技术的发展, 内燃机燃油喷射和控制,1995.1 [20」蔡向东, 外排屑深孔钻工艺参数的选择, 机械工艺师, 2000.12
[21] 孟少农, 机械加工工艺手册, 机械工业出版社, 1991
[22] 倪南良, 小孔卧式珩磨工艺余量分析, 内燃机燃油喷射和控制, 1996.4 [23〕方刚,曾攀,切削加工过程数值模拟的研究进展,力学进展,2001,31(3):394～403
[24] 李立, 珩磨原理与实践, 天津大学出版社, 1995.6
[25] 杨立, 连杆珩磨质量攻关, 天津内燃机厂论文集, 1999
[26] 何英, 表面粗糙度检测, 中国计量出版社, 1998.5
[27] 王欣玲, 表面特征国家标准应用指南, 机械工业标准化技术服务部 1997
[28] Klink,Urich;Flores,Gerhard, New technologies of honing Technical Paper-SME, Proceedings of the 1998 International Honing Conference, Apr,1998
[29] Flores,Gehard, Diamond and CBN honing technology Technical Paper-SME, Proceedings of the 1998 International Honing Conference, Apr,1998
[30] Horest O.Juchem, Honing Bores With Diamond and CBN Abrasives Cutting Tool Engineering, Dec,1986
[31] Hans H. Fischer, Honing Corrects Bore Errors, Improves Surface Finish Cutting Tool Engineering, Aug,1986
[32] E.Salje,et al, Process-Optimization in honing, CIRP Annals Vol 36,No.1,1987
[33] 章渭基, 质量控制, 科学出版社, 1988
[34] 徐扬光, 质量管理的数理统计方法, 1985
[35] 张丽敏, 柱塞偶件配磨技术与检验方法的研究, 内燃机燃油喷射和控制, 2001.1
[36] 马行, 柱塞套中孔直线度质量控制探讨, 油泵油嘴技术, 1995.1
[37] MBC-1805, 珩磨机随机用户手册
[38] 陈松川, P7 系列柱塞套中孔纯珩磨工艺, 现代车用动力, 2003.2
[39] 李良福, 加工精密孔的各种方法, 工艺与装备, 2003
[40] [日]田中义信, 精密加工法, 机械工业出版社, 1993.10
[41] 严克治, 精密微小孔电火花加工实验装置设计及实验, 南京航空学院学报, 1991.9
[42] 何家秉, 整体硬质台金枪钻在特深小孔钻削中的应用, 工具技术, 1992.10
[43] 杨逸群, 柱塞套中孔加工及装备改进的探讨, 油泵油嘴技术, 1995.1
[44] 华韬,,喷油泵柱塞偶件径部密封试验方法及参数的确定, 内燃机燃油喷射和控制, 1999,2
[45] 吴方, 李少锋, 许明凯, 喷油泵柱塞偶件配磨技术的研究[J],现代车用动力,2002(2):32~33
[46] 张丽敏,柱塞偶件配磨技术与检验方法的研究[J],内燃机燃油喷射和控制,2001(1):33~35
[47] 王琬山, 邢敏主编,机械制造手册[M],辽宁科学技术出版社,2002:499
[48] 徐宁, 精密加工技术的现状及发展前景, 机械制造 41 卷, 第 469 期
[49] 李隆章编著,质量管理中的统计方法[M],上海人民出版社 1987:4