发动机气缸体珩磨机的改进与应用
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摘要
气缸体是发动机燃烧室的重要组成部分[1]。发动机正常工作时,气缸孔处于高压、高温的恶劣环境中,活塞、活塞环在缸孔中做高速往复运动,缸孔内壁由于活塞侧压力的作用很容易磨损,造成圆柱度不良。从而使活塞与缸孔内壁密封不好,燃气泄漏量增大,机油消耗增加过高,影响发动机的功率输出和使用寿命[2]。因此气缸孔加工质量的优劣直接影响发动机的技术性能指标和使用效果。
平顶珩磨与普通珩磨相比,是一种先进的珩磨工艺,缸孔表面微观形貌呈光滑的平顶(而不是尖峰),与相对较深的波谷(与普通珩磨相比波谷较深),二者规律性地间隔分布。采用平顶珩磨工艺发动机具有磨合周期短、润滑条件好、生产效率高等优点,是目前缸孔珩磨工艺的主流。引进平顶珩磨工艺,对于提高汽车发动机的缸体质量、提高生产效率,有重要意义。平顶珩磨工艺作为目前最先进的缸孔珩磨工艺之一,这些新工艺的应用对提高发动机的使用寿命,提高发动机的燃油经济性和动力性起到了极其重要的作用,特别是对减少发动机早期磨损和降低发动机机油消耗等方面起到了至关重要的作用。
本文介绍了国内外缸孔珩磨工艺发展历程和现状,对普通珩磨、平顶珩磨工艺进行了对比研究,同时对珩磨原理进行了分析,介绍了珩磨机的加工特点和平顶珩磨的工艺技术。在此基础之上,结合多年实际工作经验及公司的实际现状,对发动机气缸体缸孔加工工艺进行改进,反复试验,并经过实际应用,取得了良好的经济效果,对提高生产质量及生产效率起到了推动作用。
Single feed honing is also general honing process, the formation of the mesh structure does not have a flateau,the support rate of surface is low, dimension precision is also low, it needs to run a certain period of time to stabilize the use of the running, it also causes high oil and fuel consumption, low power torque. Flat roofed mesh honing forms the the small groove on the cylinder surface through honing cylinder, the groove is regularly formed with mesh, it grinds the peak by specialized honing process, and forms small flateau. Its advantages are as follows:
1. Oil saving function and good lubrication. If it does not have continuous, effective and adequate oil film between the piston and cylinder hole, it will form a dry grinding and have a greater wear and tear, ultimately affect the life of the engine. It saves oil in low areas for flat roofed mesh, full lubricates friction between the ring and the wall, it is a good solution to this problem.
2. Reducing oil consumption. In the machining of flat roofed honing, peak, burr are removed, peak and burr formed as a result of general honing are removed by the cost of wear and tear piston ring and wall, and much iron chip falls into the oil pan, it need change oil frequently during engine running. It can be kept oil cleaner for flat roofed mesh technology, and reduces the chance of oil entering the combustion chamber, extends the replacement cycle oil, so as to reduces oil consumption.
3. Good at piston ring sealing. Scientific measurements and calculations show that: the bearing friction area formed of general honing is less than the total area of 5%. During the flat roofed Honing, this ratio is over 80%. With the increase in contact area, it is obviously improved for sealing piston rings.
Flat roofed mesh technology greatly improves the life of the engine, effectively reduces the use of oil and the harmful emissions, it’s more environmentally friendly, it is also an important process in a modern engine plant.
According to the original honing machine in this thesis, it made the original single-feed honing, two honing (rough honing, finish honing) into three honing (rough honing, finish honing,plateau honing), increased the active measuring device. According to the results of testing it can be carried out on the automatic compensation finish honing.
Two kinds of process test about the cylinder bore precision on the same cylinder block are made,the honing stone material and honing stone fixation methods are respectively changed. By comparing the results,analysis shows that the existing product requirements are met,but the super-hard honing stone and adhesive fixation methods can significantly improve product quality.
1. Super hard honing stone can obtain a better precision, it’s cycle time and process is stability, and cost is not high.
2. Adhesive honing stone methods may further improve the product quality,and to maintain process stability,although the replacement time is longer,but it can be resoled by more preparation of honing head.
According the test results, it can be concluded that the superhard honing of adhesive fixation methods can significantly improve cylindricity and roughness. Its processing cost is not high to compare SiC honing stone.
Changing the original silicon abrasive to diamond and CBN abrasives, the test results showed the following advantages:
1. Long life. Under reasonable conditions of use, using life of honing is 5000-10000 pieces.
2. Honing efficient. 60-90seconds/hole.
3. To improve the working conditions of workers. Honing can reduce the time to replace and adjust the honing head.
4. The precision of production is improved. It is increased more than 30% for II sub-group by the use of diamond honing than SiC honing.
The coolant is changed from oil to water-soluble, test results showed the following advantages:
1. Oil Base coolant exists the danger of fire, water base coolant has not the problem.
2. To reduce the pollution and dirty caused by spread of oil mist which is caused by spattering oil, so as to maintain a clean operating environment occasions. Energy conservation and emission reduction to meet national requirements.
3. With no corrosion, pollution-free, in line with environmental protection requirements. There are good lubrication, cleaning and cooling effect. It is more emphasis on its cleansing and cooling effect for super-hard abrasive.
4. Considering the cost, the use of water base coolant has been able to meet the application requirements, and can significantly reduce the cost of coolant
It is studied by Mitsubishi 4G64 engine block manufacturing process in this thesis. The advanced platau honing technology replaced the original general honing process. Improvements and test of the honing machine, verify the advanced nature of the flat roofed honing process. Test results show that the cost, efficiency, and performance of engine has been improved.
平顶珩磨与普通珩磨相比,是一种先进的珩磨工艺,缸孔表面微观形貌呈光滑的平顶(而不是尖峰),与相对较深的波谷(与普通珩磨相比波谷较深),二者规律性地间隔分布。采用平顶珩磨工艺发动机具有磨合周期短、润滑条件好、生产效率高等优点,是目前缸孔珩磨工艺的主流。引进平顶珩磨工艺,对于提高汽车发动机的缸体质量、提高生产效率,有重要意义。平顶珩磨工艺作为目前最先进的缸孔珩磨工艺之一,这些新工艺的应用对提高发动机的使用寿命,提高发动机的燃油经济性和动力性起到了极其重要的作用,特别是对减少发动机早期磨损和降低发动机机油消耗等方面起到了至关重要的作用。
本文介绍了国内外缸孔珩磨工艺发展历程和现状,对普通珩磨、平顶珩磨工艺进行了对比研究,同时对珩磨原理进行了分析,介绍了珩磨机的加工特点和平顶珩磨的工艺技术。在此基础之上,结合多年实际工作经验及公司的实际现状,对发动机气缸体缸孔加工工艺进行改进,反复试验,并经过实际应用,取得了良好的经济效果,对提高生产质量及生产效率起到了推动作用。
Single feed honing is also general honing process, the formation of the mesh structure does not have a flateau,the support rate of surface is low, dimension precision is also low, it needs to run a certain period of time to stabilize the use of the running, it also causes high oil and fuel consumption, low power torque. Flat roofed mesh honing forms the the small groove on the cylinder surface through honing cylinder, the groove is regularly formed with mesh, it grinds the peak by specialized honing process, and forms small flateau. Its advantages are as follows:
1. Oil saving function and good lubrication. If it does not have continuous, effective and adequate oil film between the piston and cylinder hole, it will form a dry grinding and have a greater wear and tear, ultimately affect the life of the engine. It saves oil in low areas for flat roofed mesh, full lubricates friction between the ring and the wall, it is a good solution to this problem.
2. Reducing oil consumption. In the machining of flat roofed honing, peak, burr are removed, peak and burr formed as a result of general honing are removed by the cost of wear and tear piston ring and wall, and much iron chip falls into the oil pan, it need change oil frequently during engine running. It can be kept oil cleaner for flat roofed mesh technology, and reduces the chance of oil entering the combustion chamber, extends the replacement cycle oil, so as to reduces oil consumption.
3. Good at piston ring sealing. Scientific measurements and calculations show that: the bearing friction area formed of general honing is less than the total area of 5%. During the flat roofed Honing, this ratio is over 80%. With the increase in contact area, it is obviously improved for sealing piston rings.
Flat roofed mesh technology greatly improves the life of the engine, effectively reduces the use of oil and the harmful emissions, it’s more environmentally friendly, it is also an important process in a modern engine plant.
According to the original honing machine in this thesis, it made the original single-feed honing, two honing (rough honing, finish honing) into three honing (rough honing, finish honing,plateau honing), increased the active measuring device. According to the results of testing it can be carried out on the automatic compensation finish honing.
Two kinds of process test about the cylinder bore precision on the same cylinder block are made,the honing stone material and honing stone fixation methods are respectively changed. By comparing the results,analysis shows that the existing product requirements are met,but the super-hard honing stone and adhesive fixation methods can significantly improve product quality.
1. Super hard honing stone can obtain a better precision, it’s cycle time and process is stability, and cost is not high.
2. Adhesive honing stone methods may further improve the product quality,and to maintain process stability,although the replacement time is longer,but it can be resoled by more preparation of honing head.
According the test results, it can be concluded that the superhard honing of adhesive fixation methods can significantly improve cylindricity and roughness. Its processing cost is not high to compare SiC honing stone.
Changing the original silicon abrasive to diamond and CBN abrasives, the test results showed the following advantages:
1. Long life. Under reasonable conditions of use, using life of honing is 5000-10000 pieces.
2. Honing efficient. 60-90seconds/hole.
3. To improve the working conditions of workers. Honing can reduce the time to replace and adjust the honing head.
4. The precision of production is improved. It is increased more than 30% for II sub-group by the use of diamond honing than SiC honing.
The coolant is changed from oil to water-soluble, test results showed the following advantages:
1. Oil Base coolant exists the danger of fire, water base coolant has not the problem.
2. To reduce the pollution and dirty caused by spread of oil mist which is caused by spattering oil, so as to maintain a clean operating environment occasions. Energy conservation and emission reduction to meet national requirements.
3. With no corrosion, pollution-free, in line with environmental protection requirements. There are good lubrication, cleaning and cooling effect. It is more emphasis on its cleansing and cooling effect for super-hard abrasive.
4. Considering the cost, the use of water base coolant has been able to meet the application requirements, and can significantly reduce the cost of coolant
It is studied by Mitsubishi 4G64 engine block manufacturing process in this thesis. The advanced platau honing technology replaced the original general honing process. Improvements and test of the honing machine, verify the advanced nature of the flat roofed honing process. Test results show that the cost, efficiency, and performance of engine has been improved.
引文
[1] Indrajit Mukherjee and Pradip Kumar Ray, A systematic solution methodology for inferential multivariate modelling of industrial grinding process Journal of Materials Processing Technology Volume 196, Issues 1-3, 21 January 2008
[2]韩昌满缸孔珩磨工艺的发展与应用,哈尔滨工程大学2006.7
[3]周同玉主编《机械制造技术与设备》机械工业出版社2006年8月
[4]张雄纪编著《金属切削原理及刀具》浙江:浙江大学出版社2005年6月
[5]姚坤基于中达机电技术的卧式精密珩磨机自动化解决方案--《现代制造》2007年22期
[6]吴建民数控珩磨机关键技术研究《兰州理工大学硕士论文》2005.7.4
[7]王秦生金刚石珩磨条的研制郑州机械专科学校2000年7月
[8] Simon C.Tung Modeling of Abrasive Wear in a Piston Ring and Engine Cylinder Bore System C _C Society of Tribologists and Lubrication Engineers 2004
[9]谭孝健,立方氮化硼在珩磨中的应用南方航空科技1989年02期
[10]苏达智双进给珩磨及其应用《新技术新工艺》1990年06期
[11]王永生平顶网纹珩磨《现代制造工程》1991年07期
[12]罗会斌郎静东风康明斯B系列缸体压板珩磨工艺研究《汽车科技》2003年1月
[13] ARAI MASATOSHI Two dimensional profile parameters and the trend of standards of surface texture measurement Journal of the Japan Society for Abrasive Technology (JSAT) 2002
[14]赵汝嘉陈桦王建文编著《机械加工工艺手册》,机械工业出版社2003年
[15]孟少农主编《机械加工工艺手册》机械工业出版社1996年11月
[16]熊元一郭建忠侯军丽李贵贤珩磨工艺及其在汽车零部件制造中的应用《现代汽车》2004年12
[17]刘蒲生雷力生编著《磨具选择与使用》机械工业出版社
[18]磨具制造及工作原理介绍《现代模具》2008年10月
[19]刘明耀我国超硬材料制品的新进展及发展趋势《WMEM》2003年8月第4期
[20]电镀结合剂的超硬磨料成形砂轮--《机械科学与技术》1993年06期
[21]傅玉灿徐鸿钧超硬磨料砂轮的演变与发展──介绍国外新型的单层高温钎焊超硬磨料砂轮《金刚石与磨料磨具工程》1999年03期
[22]杨钧杰CBN砂轮在数控小专机上的应用《精密制造与自动化》2008年第4期
[23] Neagu, C.;Cristea, R.;Dumitrescu, A.;Bayer, M. Cutting parameter optimization in cast-iron honing with diamond tools UPB Scientific Bulletin, Series D: Mechanical Engineering,UPB Sci Bull Ser D,1220-3041,3,60,p 349-355,1998,English
[24]孙美玲赵宏德珩磨加工原理及其工艺参数的选择《黑龙江科技信息》2004年第1期
[25]张云电,李国栋,钟美鹏低碳钢珩磨过程中珩磨力的分析与试验研究<<机电工程>> 2002年第19卷第04期
[26]董丽君深孔珩磨加工中的常见质量缺陷及其产生原因《科技情报开发与经济》2006年第1期
[27] Naoki Iijima Takeshi Yamada , Cylinder Honing Angle and Friction of Piston and Piston Rings, 2006 JSAE Annual Congress (Spring) ,2006年1月1日
[28]孙琦平顶网纹珩磨技术在北京型柴油机气缸套加工中的应用《机车车辆工艺》1996年3月
[29]宋昭祥编著《现代制造工程技术实践》,机械工业出版社2008年7月
[30]永钧正确使用超硬磨具《中国研磨》2009年3月第七期
[31] Ya. M. Kershenbaum, Zh. M. Mostovaya, M. V. Mikhailover and I. M. Timokhin Selection of a coolant for diamond honing Chemical and Petroleum Engineering 2005.2.8
[32]汪德涛《润滑技术手册》机械工业出版社1999年4月
[33] Javad Akbari A n Experimental Study on Bore Honing Operation Initiatives of Precision Engineering at the Beginning of aMillennium 2001
[34]肖飞来基于不同安装主轴类型的珩磨系统.《新技术新工艺》, 2001,3
[35]苏达智双进给珩磨机及其应用《制造技术与机床》1989年09期
[36]贾秀杰梁明柱李剑峰《金刚石平台网纹珩磨工艺及加工参数分析》磨料模具通讯2005年第5期
[37]左敦稳编著《现代加工技术》北京航空航天大学出版社2009年
[38]张云电编著《现代珩磨技术》科学出版社2007年6月
[39]李玉杰《机械工人.冷加工》2003年10期
[40]葛延翔郑云龙缸孔平台珩磨工艺及评定方法《汽车制造业》2004年第6期
[41] Yongkang ZhangChaojun YangYonghong Fu Surface Texturing Technology by Laser Honing Based on Hydrodynamic Lubrication Advances in Grinding and Abrasive Technology XIV 2007.1.1
[42] KUNIKI TOSHINORI, Cylinder block bore honing, Journal of the Japan Society for Abrasive Technology (JSAT), 2004年
[43]晏初宏缸套珩磨工艺参数的选择《金属切削机床》机械工业出版社2007年9月
[44]何无忌《机械工人.冷加工》1995年09期刊号:199510
[2]韩昌满缸孔珩磨工艺的发展与应用,哈尔滨工程大学2006.7
[3]周同玉主编《机械制造技术与设备》机械工业出版社2006年8月
[4]张雄纪编著《金属切削原理及刀具》浙江:浙江大学出版社2005年6月
[5]姚坤基于中达机电技术的卧式精密珩磨机自动化解决方案--《现代制造》2007年22期
[6]吴建民数控珩磨机关键技术研究《兰州理工大学硕士论文》2005.7.4
[7]王秦生金刚石珩磨条的研制郑州机械专科学校2000年7月
[8] Simon C.Tung Modeling of Abrasive Wear in a Piston Ring and Engine Cylinder Bore System C _C Society of Tribologists and Lubrication Engineers 2004
[9]谭孝健,立方氮化硼在珩磨中的应用南方航空科技1989年02期
[10]苏达智双进给珩磨及其应用《新技术新工艺》1990年06期
[11]王永生平顶网纹珩磨《现代制造工程》1991年07期
[12]罗会斌郎静东风康明斯B系列缸体压板珩磨工艺研究《汽车科技》2003年1月
[13] ARAI MASATOSHI Two dimensional profile parameters and the trend of standards of surface texture measurement Journal of the Japan Society for Abrasive Technology (JSAT) 2002
[14]赵汝嘉陈桦王建文编著《机械加工工艺手册》,机械工业出版社2003年
[15]孟少农主编《机械加工工艺手册》机械工业出版社1996年11月
[16]熊元一郭建忠侯军丽李贵贤珩磨工艺及其在汽车零部件制造中的应用《现代汽车》2004年12
[17]刘蒲生雷力生编著《磨具选择与使用》机械工业出版社
[18]磨具制造及工作原理介绍《现代模具》2008年10月
[19]刘明耀我国超硬材料制品的新进展及发展趋势《WMEM》2003年8月第4期
[20]电镀结合剂的超硬磨料成形砂轮--《机械科学与技术》1993年06期
[21]傅玉灿徐鸿钧超硬磨料砂轮的演变与发展──介绍国外新型的单层高温钎焊超硬磨料砂轮《金刚石与磨料磨具工程》1999年03期
[22]杨钧杰CBN砂轮在数控小专机上的应用《精密制造与自动化》2008年第4期
[23] Neagu, C.;Cristea, R.;Dumitrescu, A.;Bayer, M. Cutting parameter optimization in cast-iron honing with diamond tools UPB Scientific Bulletin, Series D: Mechanical Engineering,UPB Sci Bull Ser D,1220-3041,3,60,p 349-355,1998,English
[24]孙美玲赵宏德珩磨加工原理及其工艺参数的选择《黑龙江科技信息》2004年第1期
[25]张云电,李国栋,钟美鹏低碳钢珩磨过程中珩磨力的分析与试验研究<<机电工程>> 2002年第19卷第04期
[26]董丽君深孔珩磨加工中的常见质量缺陷及其产生原因《科技情报开发与经济》2006年第1期
[27] Naoki Iijima Takeshi Yamada , Cylinder Honing Angle and Friction of Piston and Piston Rings, 2006 JSAE Annual Congress (Spring) ,2006年1月1日
[28]孙琦平顶网纹珩磨技术在北京型柴油机气缸套加工中的应用《机车车辆工艺》1996年3月
[29]宋昭祥编著《现代制造工程技术实践》,机械工业出版社2008年7月
[30]永钧正确使用超硬磨具《中国研磨》2009年3月第七期
[31] Ya. M. Kershenbaum, Zh. M. Mostovaya, M. V. Mikhailover and I. M. Timokhin Selection of a coolant for diamond honing Chemical and Petroleum Engineering 2005.2.8
[32]汪德涛《润滑技术手册》机械工业出版社1999年4月
[33] Javad Akbari A n Experimental Study on Bore Honing Operation Initiatives of Precision Engineering at the Beginning of aMillennium 2001
[34]肖飞来基于不同安装主轴类型的珩磨系统.《新技术新工艺》, 2001,3
[35]苏达智双进给珩磨机及其应用《制造技术与机床》1989年09期
[36]贾秀杰梁明柱李剑峰《金刚石平台网纹珩磨工艺及加工参数分析》磨料模具通讯2005年第5期
[37]左敦稳编著《现代加工技术》北京航空航天大学出版社2009年
[38]张云电编著《现代珩磨技术》科学出版社2007年6月
[39]李玉杰《机械工人.冷加工》2003年10期
[40]葛延翔郑云龙缸孔平台珩磨工艺及评定方法《汽车制造业》2004年第6期
[41] Yongkang ZhangChaojun YangYonghong Fu Surface Texturing Technology by Laser Honing Based on Hydrodynamic Lubrication Advances in Grinding and Abrasive Technology XIV 2007.1.1
[42] KUNIKI TOSHINORI, Cylinder block bore honing, Journal of the Japan Society for Abrasive Technology (JSAT), 2004年
[43]晏初宏缸套珩磨工艺参数的选择《金属切削机床》机械工业出版社2007年9月
[44]何无忌《机械工人.冷加工》1995年09期刊号:199510