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1CylinderblockmachiningprocessdesignEnginepartsengineblockisamorecomplexstructureofsparepartsbox,itshighprecision,complexprocess,andtheprocessingqualitywillaffecttheoverallperformanceengine,soithasbecometheenginemanufacturersfocuspartsone.TechnicalCharacteristicsoftheenginecylinderblockCylindercastforawholestructure,anditsupperpart4cylindermountingholecylinderstandardcylinderisdividedintoupperandlowerdivisionsintotwopartscylindertotherearofthefrontsidearrangementofthepreviousthreecoaxialmountingholeofthecamshaftandtheidleraxlehole.Cylinderprocessfeaturesarethestructureofcomplexshapeprocessingplane,morethanholesunevenwallthicknessandstiffnessislowprocessingofhighprecisiontypicalofboxtypeprocessingpart.Themainprocessingofthesurfaceofcylinderblocktopsurface,themainbearingside,cylinderbore,themainandcamshaftbearingboreholesandsoon,theywilldirectlyaffectthemachiningaccuracyoftheengineassemblyprecisionandperformance,mainlyrelyonprecisionequipment,industrialfixturesreliabilityandprocessingtechnologytoensurethereasonableness.1.EngineblockprocessdesignprinciplesandthebasisforDesignTechnologyprogramshouldbetoensureproductqualityatthesametime,givefullconsiderationtotheproductioncycle,costandenvironmentalprotectionbasedontheenterprisesabilitytoactivelyadoptadvancedprocesstechnologyandequipment,andconstantlyenhancetheirleveloftechnology.Engineblockmachiningprocessdesignshouldfollowthefollowingbasicprinciples1Theselectionofprocessingequipment,theprincipleofselectionadoptedtheprincipleofselectionadoptedtheprincipleofcombiningrigidflexible,processingeachhorizontalmachiningcenterislocatedmainlysmalloperationswithverticalmachiningcenter,thekeyprocessacrankhole,cylinderhole,balancershaftholeHighspeedprocessingofhighprecisionhorizontalmachiningcenter,anupperandlowernoncriticalprocessesbeforeandafterthefourdimensionalhighefficiencyroughmillingandhaveacertainadjustmentrangeofspecialmachineprocessing2focusonakeyprocessinprincipleprocessthebodycylinderbore,crankshafthole,BalanceShaftholesurfacefinishingandthecombinationofprecisionmillingcylinderhead,usingaprocessfocusedonasetupprogramtocompleteallprocessingelementsinordertoensureproductaccuracyThekeyqualityprocessestomeetthecylindercapacityandtherelevant2technicalrequirementsAccordingtothetechnologicalcharacteristicsofautomobileenginecylinderblockandtheproductionmandate,theengineblockmachiningautomaticproductionlineiscomposedofhorizontalmachiningcenterCWK500andCWK500Dmachiningcenters,specialmilling/boringmachine,verticalmachiningcentersmatec30Landotherappliances.1topandbottom,andtilecoveredonlythecombinationofapertureroughmillingmachinededicatedtothismachinetodoublesidedhorizontalmillingmachine,usingmovingtabledrivenparts,machinetoolsimportedSiemensS7200PLCsystemcontrol,machinecontrolcabinetsetupanindependent,cuttingautomatetheprocessiscompletedandtwokindsofautomaticandadjustthestate2highspeedhorizontalmachiningcentermachiningcentercanberealizedCWK500themaximumflowofwetprocessing,butbecauseofequipment,automaticBTAtreatmentsystemthroughthebuiltintrayunderthewidetypechipconveyorandthecompletionofthemachiningcentercanbedryprocessingmachinetoolspindlespeed6000r/min,rapidfeedingspeed38m/min3ThecombinationoffrontandrearfaceroughmillingmachinetoolusinghydraulictransmissioncontrolsystemimportedSiemensS7200PLCsystemcontrol,machinetoolshaveacertainflexibility4ThespecialmachineTXK1500thismachineverticalmachiningcenterbythemodificationofshape,withverticalmachiningcenterfeaturesandperformance,thismachinehashighstrength,highwearresistant,highstability,highaccuracy,highprofileetc.5highspeedverticalmachiningcentermatec30Lofthemachiningcenterspindlehighspeed9000r/min.ControlsystemusesSiemensSINUMERIK840Dcontrolsystem6highspeedhorizontalmachiningcenterspindleCWK500Dhighestspeed15000r/min.2.EngineblockmachiningprocessdesignthemaincontentEngineblockcomplexstructure,highprecision,argesize,isthinwalledparts,thereareanumberofhighprecisionplaneandholes.Engineblockmachiningprocesscharacteristicsmainlyflatandtheholeprocessing,processingofflatgenerallyuseplaning,millingmethodssuchasprocessing,processingofholeusedmainlyboring,processingandmultipurposedrillingholes.Asthecylindercomplexstructure.sohowtoensurethatthemutualpositionofthesurfaceprocessingprecisionisanimportantissue.3.1TheselectionofblankEngineblockonthematerialsusedaregenerallygraycastironHT150,HT200,HT250,thereisalsocastaluminumorsteelplate,thisengineblockusinghighstrengthalloycastiron.Cylinderintheprocessingpriortoagingtreatmentinordertoeliminatestressandimprovetheroughcastingmechanicalproperties.Improvetheroughaccuracy,reductionofmachiningallowance,istoimprovetheautomatedproductionlinesystemproductivityandprocessingqualityoftheimportantmeasures.Asthe3foreignboxtypepartsofroughqualityandhighprecision,anditsproductionlinesystemhasbeenimplementeddirectlyontheblankline,notonlyeliminatingtheneedforblankcheckdevicealsosavestheroughqualityproblemsduetowasteofmachiningtime,increaseoverallefficiency.Therefore,therefinementofroughistoimprovetheproductivityofthemostpromisingwayout.Fortheengineblockproductionline,canberoughinpartsonlinepremillingsixface,removingmostofthemargin,tofacilitatedirectonlineparts.3.2MachiningprocessselectionandprocessingofthebenchmarkChoosetherightprocessingtechnologybaseisdirectlyrelatedtotheprocessingqualitycanensuretheparts.Generallyspeaking,processbenchmarkingcanbedividedintocoarseandfinereferencebase.1Thebaselinefortheonlinethickrough,whichisparticularlyimportantthechoiceofbenchmarkcrude,ifcrudebenchmarkchoiceunreasonable,willtheunevendistributionofmachiningallowance,processingandsurfaceoffsets,resultinginwaste.Inthecylinderproductionline,wehaveadoptedforthecoarsesideofthebase2Refinedthebaseofthisboxfortheengineblockparts,thegeneraluseofsidetwosalesforafullrangeofuniformbenchmarks,Forthelongerautomatedproductionpositioning,therefore,willbedividedinto23segmentpinholesused.Inthecylinderpinholeoftheprocess,wehaveadoptedtotheside,bottomandthespindleholepositioning,intheprocessingcenterontheprocess.3.3MachiningProcessingStagesandprocessesofthearrangementsOftenapartofmanyapparentneedforprocessing,ofcourse,thesurfacemachiningaccuracyaredifferent.Processingofhighprecisionsurface,oftenafterrepeatedprocessingAsfortheprocessingofthesurfaceoflowprecision,onlyneedtogothroughoneortwoonthelist.Thus,whenthedevelopmentprocessinordertoseizetheprocessinghighprecisionsurface,thisconflict,thereasonablearrangementprocessesandrationaldivisionstageofprocessing.Arrangetheorderoftheprincipleofprocessisafterthefirstcoarserefined,thefirstsurfaceafterthehole,thefirstbenchmarkother.Intheengineblockmachining,thesameshouldfollowthisprinciple.1roughingstageengineblockmachiningprocess,thearrangementsforroughingprocess,tofullycarryoutroughrough,trimmostofthemargininordertoensureproductionefficiency2semifinishingphaseoftheengineblockmachining,inordertoensuretheaccuracyofthemiddleofsomeimportantsurfaceprocessing,andarrangesomesemifinishingoperations,willberequiredaccuracyandsurfaceroughnessofthesurfaceofthemiddleofsomeprocessingtocomplete,whiledemandingthesurfaceofsemifinished,toprepareforfuturefinishing3Thefinishingstageofrequiringhighaccuracyandsurfaceroughnessofthesurfaceprocessing4secondaryprocessing,suchassmallsurfacescrewholes,youcanfinishofthemajorsurfaceaftertheonehand,whentheworkpiecedeformationprocesslittleimpactatthesame4timealsoreducedtherejectionrateInaddition,ifthemainsurfaceofawaste,thesesmallthesurfacewillnothavetobeprocessed,thusavoidingawasteofmanhours.However,iftheprocessingisveryeasyforasmallsurfacebumpsthemainsurface,itshouldbeplacedonasmallsurfacefinishpriortothemainsurfacefinishing5shouldmakeproperarrangementsforsecondaryprocessessuchasproductinspectionprocess,inpartroughingstage,thekeyprocessbeforeandafterprocessing,sparepartsalltheprocessinghasbeencompleted,shouldbeappropriatearrangements.Stageofprocessingdivision,hasthefollowingadvantagesFirst,itcantakemeasurestoeliminatetheroughworkpieceafterthestress,toensureaccuracysecond,finishingontheback,andwillnotdamageduringtransportthesurfaceoftheworkpiecehasbeenprocessedagain,firstroughingthesurfacedefectscanbedetectedearlyandpromptlydealwithrough,donotwasteworkinghours.Butmostsmallparts,donotsubverythin.3.4cylindersurfaceofthemainprocessingandsecondaryprocessesCylindersurfaceandsupportthemainprocessingoperationsare1planeprocessingatpresent,themillingofengineblocksistheprimarymeansofplanarprocessing,domesticmillingfeedrateisgenerally300400mm/min,andforeign20004000mm/minmillingfeedratecomparedtofarcry,tobeonincreasing,therefore,improvethemillingfeedrate,reduceoverheadtimeistoimprovetheproductivityofthemajormeansoffinishinganumberofplaneengineblockwhenthemillingfeedratetoreach2399mm/min,greatlyimprovedefficiencyTopsurfaceofthecylindermillingisakeyprocessintheprocess,theflatnessrequirementsfor0.02/145mm,thesurfaceroughnessofRa1.6um.Processinginthecylinder,theuseofsideandspindlebearingborepositioning,top,bottomandmiddlevagayonlyaperturewhileprocessingusedintheprocessinglineoutsideoftheknifedevicecanbettermeettheengineblockmachiningaccuracy2Generalholesmachiningholesingeneralarestillusingthetraditionalprocessingofdrilling,expansion,boring,reaming,tappingandothercraftapproach.Issuesinthedesignprocessofspecificprograms,useofcoatedcuttingtools,cuttingtoolsandotheradvancedtoolswithinthecooling,andusingalargeflowofcoolingsystems,greatlyimprovingthecuttingspeed,improvedproductivity3deepholeprocessingofthetraditionalprocessingmethodisusedtogradetwistdrillfeed,lowefficiencyoftheirproduction,processingandqualityispoor.Thedeepholeintheengineblockprocessing,theuseofgundrillingprocess4Thethreeaxismachiningholesforthecylinderaxismachiningholesholesofhighprecision,longworkinghoursoftherestrictiveprocess.Thus,workarrangements,processingmethods,toolsandsoonshouldbespecialattention.Allcoverpreprocessing,thatis,semicircularholeandthecylinderblockmainbearingcapoftheshortageofprocessing,itsmainpurposeistoremoveblankmargin,releasestress,toprepareforthepostorderprocessingincrankshaft
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