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汽车发动机附件箱多孔加工专机的设计【4张CAD图纸和说明书】

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编号:15104717    类型:共享资源    大小:1.14MB    格式:RAR    上传时间:2019-02-27 上传人:俊****计 IP属地:江苏
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4张CAD图纸和说明书 汽车发动机附件箱多孔加工专机的设计 张CAD图纸 图纸加工设计cad 设计【4张CAD图纸 4张CAD图纸 张CAD图纸和说明书】 设计cad图纸
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摘  要


论文完成了汽车发动机箱体的多个孔的专用机床的设计,要求一次装夹完成驱动桥壳孔的加工,保证孔位置精度和其他加工要求。通过对原始数据(材料,尺寸及加工要求)的分析计算,确定了刀具的切削用量,机床配置形式,并计算出主轴的切削功率和转速,合理选择机床的通用部件及设计相配套的夹具。采用卧式组合机床进行零件的加工,配以转角液压缸夹紧,提高工件的装夹速度。设计的组合机床提高了机床加工精度,保证被加工零件的加工要求,且工作稳定,操作方便,减少了加工时间,提高了工作效率。


关键词:组合机床;专用夹具;驱动桥壳;零件 


ABSTRACT


Thesis completed automobile engine box of a plurality of holes special machine design, requirements to complete a fixture drive axle hole machining, hole locations to ensure the accuracy and other processing requirements. The original data (material, size, and processing requirements) analysis and calculation to determine the cutting tool, machine tool configurations, and calculate the spindle cutting power and speed, a reasonable choice of common components and design tools supporting the fixture. A horizontal combination machine for machining, hydraulic cylinder with corner clamp, improve workpiece clamping speed. The combination tool designed to improve the machining accuracy, and ensure the processing requirements of parts to be machined, and job stability, easy to operate, reducing the processing time, improve work efficiency.

    

Keywords: combination machine; special fixtures; drive axle housing; Parts


前   言

组合机床是凭借通用部件为基础,并按照工件特定形状和加工工艺为其设计专用部件和夹具,组成的半自动或自动专用机床。组合机床一般采用多轴、多刀、多工序、多面或多工位同时加工的方式,生产效率要比通用机床高几倍乃至几十倍。由于选用标准化和系列化的通用部件,根据需要灵活配置,能缩短机床设计和制造周期。因此,组合机床兼有低成本和高效率的优点,在汽车、拖拉机、柴油机、电机、仪表、军工及缝纫机、自行车等轻工业行业大批大量生产中已获得广泛应用。

组合机床一般用于加工箱体类或特殊形状的零件。加工时,工件一般不旋转,由刀具的旋转运动和刀具与工件的相对进给运动,来实现钻孔、扩孔、锪孔、铰孔、镗孔、铣削平面、切削内外螺纹以及加工外圆和端面等。

近年来,组合机床不仅在数量和品种上有了很大的发展,而且在加工工艺、机床配置型式、适用范围和控制技术等方面都有不少的创新和发展:随着科技的发展,关键技术问题的攻关,组合机床朝着柔性化、数控化、高精度、高生产率、多品种、短周期、组合机床及其自动线超高速和超高精度方向发展!

机床夹具是在机床上加工零件时所使用的一种工艺设备,主要用于实现工件的定位和加紧,使工件加工时相对于机车、刀具有正确的位置、以保证工件的加工质量和生产率的要求。组合机床夹具更是保证工件能正常加工,达到规定要求的重要部件。

本课题所设计的组合机床,刀具对工件的加工顺序为平行加工,组合机床的配置形式为单面。机床带有一套固式定夹具,根据所需的加工面数布置动力部件,动力部件选择为:卧式,工件安装在机床的固定夹具里,夹具和工件固定不动,动力滑台实现进给运动,滑台上的动力箱连同多轴箱实现切削运动设计过程中,既需要考虑实现工艺方案,保证加工精度、技术要求及生产率,又考虑到机床操作、维护、修理、排屑的方便性。

此次课程设计,分为组内分工设计。组内成员分别设计夹具和多轴箱,配合完成组合机床整套设计。此设计为组合机床及其夹具部分设计。在组员多轴箱设计同学的辅助下顺利完成设计。

本课程设计的完成,主要依赖于指导老师无私的指导讲解、大学几年的努力、网上查阅的各种相关资料、图书馆无数的纸质文件以及自身的不懈奋斗。其中老师的指导,更是起了关键性的作用,所谓画龙点睛之笔!

本次课程设计虽说顺利完成,却也困难重重。但这些也正好为以后走上工作岗位提高了实习经验,尤其是如何遵循理论又不拘泥于理论,这对缺乏实践经验的我来说是个挑战。



目录

摘  要 III

ABSTRACT IV

前   言 V

1  绪论 1

1.1组合机床的组成及特点 1

1.2多轴箱设计介绍 1

1.3液压系统 2

2 零件加工工艺分析 5

2.1零件的作用 5

2.2零件工艺分析 5

2.3工艺规程设计 5

2.4本工序工艺方案的拟订 6

3 切削用量的确定 6

3.1加工内容及切削用量参数表 7

3.2确定切削力F(N)、切削转矩T(N•mm)、切削功率P(kw) 7

4 组合机床总体设计 16

4.1被加工零件工序图 16

4.1.1 被加工零件工序图的作用与内容 16

4.1.2 绘制被加工零件工序图的规定及注意事项 16

4.2加工示意图 17

4.3机床联系尺寸总图 20

4.3.1 机床联系尺寸总图的作用于内容 20

4.3.2绘制机床联系尺寸之前应确定的主要内容 20

4.3.3 机床分组 22

4.4机床生产率计算卡 22

4.4.1理想生产率Q 22

4.4.2实际生产率Q1 23

4.4.3机床负载率η负 23

5 专用夹具设计 24

5.1制定设计方案 25

5.1.1确定夹紧方式,设计夹紧机构。 25

5.1.2夹具夹紧力分析 26

5.2绘制夹具装配总图 26

图5.1夹具装配图 27

5.3绘制夹具零件图 28

6 专用多轴箱的设计 29

6.1多轴箱的功用及分类 29

6.2专用多轴箱的组成 29

6.3专用多轴箱的传动系统设计 29

6.4专用多轴箱的设计 31

6.5 润滑泵的选择 33

6.6其他相关部件的选择 34

7 结论 36

致谢 37

参考文献 38


1  绪论

1.1组合机床的组成及特点

组合机床是根据工件加工需要,以大量通用部件为基础,配以少量专用部件组成的一种高效专用机床。

通用部件是组成组合机床的基础,是具有特定功能,按标准化、系列化、通用化原则设计制造的组合机床基础部件。它具有统一的联系尺寸标准,结构合理,性能稳定。组合机床的通用化程度是衡量其技术水平的重要标志。通用部件按其功能通常分为五大类:动力部件,支撑部件、输送部件、控制部件和辅助部件。用来传递动力,实现工作运动的通用部件如动力滑台、动力箱、具有各种工艺性能的动力头称为动力部件。用于安装动力部件、输送部件等的通用部件如侧底座、中间底座、立柱、立柱底座、支架等称为支撑部件。

组合机床的特点:

1)主要用于棱体类零件和杂件的孔面加工。

2)生产率高。因为工序集中,壳多面、多工位、多组、多刀同时自动加工。

3)加工精度稳定。因为工序固定,壳选用成熟的通用零件、精密夹具和自动工作循环来保证加工精度的一致性。

4)研制周期短,便于设计、制造和使用维护,成本低。因为通用化、系列化、标准化程度高,通用零件占70-90,通用件壳组织批量生产进行预制或外购。

5)自动化程度高,劳动强度低。

6)配置灵活。因为结构模块化、组合化。可按工件或工序要求,用大量通用部件和少量专用部件灵活组成各种类型的组合机床或生产线;机床易于改装;

产品或工艺变化时,通用部件一般还可以重复利用。


内容简介:
中文译文 发动机缸盖加工工艺概述一、发动机缸盖的功用 气缸盖是发动机的主要零件之一,位于发动机的上部,其底平面经汽缸衬垫,用螺栓紧固在气缸体上。主要功用如下:1、封闭气缸上部,并与活塞顶部和汽缸壁一起形成燃烧室。2、作为定置气门发动机的配气机构、进排气管和出水管的装配基体。3、气缸盖内部有冷却水套,其底面上的冷却水孔与气缸体冷却水孔相通,以便利用循环水带走发动机的高温。二、气缸盖的结构特点气缸盖应具有足够的强度和刚度,以保证在气体的压力和热应力的作用下,能够可靠的工作。气缸盖的形状一般为六面体,系多孔薄壁件,其中我们现在481缸盖上,加工的数量多达100个。铸造最薄处只有4.5毫米。 三、缸盖材料与毛坯制造1、缸盖的材料: 缸盖的材料,现在的发动机厂家一般选用铝合金。因为铝合金导热性能较好,有利于适当提高压压缩比,质量也较轻,可以降低整车、整机的重量。但是铝合金缸盖的刚度差,使用过程中容易变形。 缸盖附件上,以前气门座材料一般采用耐热合金铸铁,气门导管一般采用铸铁。现在粉末冶金在气门阀座和导管上运用的越来越多了,而且很多复杂的形状也能铸造成型,不需要再加工了。但耐磨性不如铸铁。 裂纹:铸造应力造成; 冷隔:浇注过程中铝水冷却速度不一致造成; 表面疏松:浇注温度不当或铝水成分不当; 气孔:浇注铝水中夹杂了空气; 砂眼:浇注铝水中夹杂了杂质; 沾砂:工件出炉温度不当或没有喷丸等。四、缸盖的加工难点:1、平面加工工艺 缸盖的顶面、底面和进、排气面都是大面积平面,精度要求高(平面度0.04,垂直度0.05,位置度0.10),而且有可能是全部工艺过程的基础,例如480缸盖就是。 这就对机床的几何精度和刀具的调整精度要求比较高。 以前缸盖大平面加工,采用硬质合金刀片加工,并配一个金刚石修光刃。现在,如果毛坯情况好的话,全部采用金刚石刀片进行加工,可以很好的提高加工后的表面粗糙度。2、高精度孔的加工 气缸盖上的气门阀座、导管孔、挺杆孔和凸轮轴孔等孔系,有配合关系。其尺寸精度、位置精度和表面粗糙度要求极为严格。所以这些高精度孔系的加工工序是缸盖工艺中的核心工序,应给予充分的重视。 1)、缸盖气门阀座、气门导管精加工 缸盖气门阀座、气门导管同时与发动机气门配合,所以同轴度要求比较高;另外气门阀座与气门锥面进行密封配合,对于圆度要求也非常高。 对于上述部位的加工过程,现在480缸盖分解如下: 机床主轴快进-工进-主轴重新启动,加工气门阀座锥面-主轴停止、并后退一端距离-主轴重新启动,枪铰加工气门导管(干通) -加工完毕-工进退刀-主轴回推。 这样做的好处,就是一次定位,加工完毕气门导管和气门阀座,可以减少重复定位误差,提高气门导管和气门阀座的同轴度。 另外,主轴在重新启动后,加工气门阀座的时候,进刀方向如果沿着阀座径向方向,此种加工方式成为“车”阀座,可以提供加工精度。如果进刀方向沿着阀座轴向方向,称为“锪”或 “镗”阀座。 因为气门阀座和气门导管材料的变化,加工过程中选用的刀具也在不断的发生变化。以前的硬质合金刀片逐渐被CBN刀片所替代,很大的提供了加工效率和加工质量。并且,如果有铜基粉末冶金材料的气门阀座和气门导管,还可以采用PCD刀片进行加工。 2)、缸盖挺杆孔、气门导管底孔的加工 这些孔的加工,虽然加工精度比较高,但是,只要选好加工余量、参数和刀具,加工过程基本没有什么问题。 3)、缸盖凸轮轴孔的加工 缸盖凸轮轴孔,就是缸盖最长的孔,如果分段加工的话,虽然可以保证凸轮轴孔的加工精度,但是无法满足凸轮轴孔的同轴度要求,所以要求精加工一次加工成型。对于长度为500mm左右的刀杆而言,如何消除刀杆自身重力所产生的影响? 对于专机自动线而言,一般都带有镗模架以消除影响,对于比较大的发动机,有可能带有好几个镗模架。 对于加工中心,现在基本已经取消镗模架,利用刀具的自导向来消除刀杆重力的影响。刀杆的结构特点是:在刀杆的圆周上,均匀布置一个刀刃和三个导向条。刀杆数量一般是一长一短。 加工过程如下: 先由短刀杆加工一个凸轮轴孔(至半精加工尺寸)-退刀-长刀杆完成所有凸轮轴孔的半精、精加工。 4)、缸盖加工过程的毛刺 对于铝合金缸盖,因为是塑性材料,加工过程中不可避免的产生毛刺。 对于加工过程中的毛刺,除了要合理的选用加工参数、刀具参数外,还可以提高工件材料的硬度,也可以弱化加工过程中毛刺的产生。 现在加工过程中,主要有以下几种方式去除加工毛刺: 一、尼龙毛刷去毛刺,多用于大的加工表面和大的孔系去毛刺; 二、高压水去毛刺,多用于深油孔去毛刺,也有利用旋转水柱去大面或大孔的毛刺;三、表面喷丸或表面抛丸:多用于铸件表面的毛刺、飞边处理,影响工件的清洁度;四、电火花去毛刺:用于比较难去除的毛刺,比如合金钢的毛刺,对于不规则的毛刺,去除比较困难;五、氢氧爆破去毛刺:利用氢氧燃烧产生的压力和高温气流,将附于工件表面产生的毛刺消除,但是对于工件毛坯要求比较高,补焊、裂纹、冷隔都有可能导致工件报废。 5)、缸盖的清洗 缸盖清洗工序是缸盖的主要辅助工序之一。因为发动机对缸盖的清洁度要求非常严格(我们现在AVL缸盖的清洁度指标为:7mg),而缸盖又是一个多孔型腔组成的复杂铸造箱体,如清洗不彻底而使砂子和铝屑等进入发动机的润滑系统或汽缸中,则会直接影响发动机的工作和使用寿命。所以,应该充分重视缸盖的清洗工序。 对于缸盖清洗机而言,现在一般都带有射流清洗工位,相当于预清洗工位,工件在水箱中翻转,清洗喷嘴带有压缩空气的水流,从而达到工件粗步清洗的效果。 对于有装配需求或不易清洗干净之处,清洗机上一般配备有顶点定位清洗工位,就可以将规定部位清洗干净了。但会导致机床长度增加、喷嘴布置不方便等,而且还无法满足柔性清洗的需求。 对于缸盖水道的清洗,因为受到毛坯铸造质量的影响比较大,所以也是一个清洗难点。五、典型缸盖加工工艺流程 下面我们以AVL缸盖的加工工艺流程为例,了解在加工中心上是如何加工缸盖零件的: OP10:毛坯上料; OP20:毛坯基准定位,加工缸盖进、排气面(除了进气侧面油孔不加工外); OP30:排气侧面精基准定位,加工缸盖顶面、前、后端面的加工内容; OP40:排气侧面精基准定位,加工缸盖顶面、燃烧室面的加工内容;OP60:清洗工序;OP70:缸盖水道和油道试漏;OP80:缸盖气门阀座、气门导管装配(常温装配);OP90:缸盖凸轮轴盖、定位销装配,凸轮轴盖螺栓自动拧紧;OP100:排气侧面精基准定位,完成缸盖顶面和燃烧室面的精加工(气门导管和气门阀座的精加工);OP110:排气侧面精基准定位,完成缸盖凸轮轴孔和前、后端面的精加工;OP120:终清洗工序;OP130:涂胶、压装碗形塞、钢球;OP140:试漏机;OP150:目视检测;OP160:打号工序;OP170:成品下料。 从上面的工艺流程来看,已经运用了加工中心制造技术、敏捷制造技术等较为现在的生产线制造技术。 另外,为了更好的进行多品种共线生产,缸盖的设计、工艺基准都在向排气侧转化,以便更好的进行共线生产。六、缸盖加工的注意事项:1、缸盖尺寸较大时,由于内应力重新分布而产生变形,会严重影响缸盖的加工精度。一般的原则就是先面后孔,粗加工和精加工尽量分散,以保证加工应力的释放。2、为了避免缸盖结合面划伤,一般将结合面精加工尽量放在后续工序。3、振动清理内腔铁屑杂物工序,应安排在与水腔有关的加工工序以后最为适宜。免得震动清理后,又加工与水腔有关的部位,又有铁屑掉进去,以后还需要进行清洗。4、加工过程中,特别是自动化大批量加工过程中,最好带有夹具喷气检测和刀具折断检测,以减少加工过程中,不必要的损失。七、结束语 以上就是发动机缸盖加工工艺的概述,真正的知识来自于现场,来自于时间。英文原文Overview of engine cylinder head machining process First, the function of the engine cylinder headCylinder head of the engine of the main parts, the upper part of the engine, the cylinder liner via the bottom plane, with bolts on the cylinder body. The main function is as follows: 1, the closed upper cylinder and the piston and the cylinder wall at the top with a combustion chamber. 2, as a set-valve engine valve train, intake and exhaust pipe and the outlet pipe assembly base. 3, inside the cylinder head cooling water jacket, the bottom surface of the cooling water hole of the cylinder block cooling water hole communicating in order to use the engine temperature circulating water away. Second, the structural characteristics of the cylinder head the cylinder head should have sufficient strength and rigidity to ensure that the gas pressure and under the action of thermal stress, work reliably. cylinder head shape is generally hexahedral, based porous thin pieces, of which we are now 481 cylinder head, processing up to 100 the number of holes. Casting is only 4.5 mm at the thinnest. Third, the head material and blank manufacturing 1, cylinder head material: Cylinder head material, and now the engine manufacturers generally use aluminum. Because aluminum thermal conductivity is better, is conducive to an appropriate increase in pressure compression ratio, the quality is also lighter, you can reduce the vehicle, the whole weight. But the difference in stiffness aluminum alloy cylinder head, easily deformed during use. cylinder head attachment, previously valve seat material commonly used heat-resistant alloy cast iron, cast iron valve guides commonly used. Powder metallurgy is now the seat of the valve and conduit on the use of more and more, and many complex shapes can also be casting, without reprocessing it. However, abrasion resistance than cast iron. Crack: casting stress caused; Cold compartment: aluminum casting process water cooling rate caused inconsistent; loose surface: aluminum water pouring temperature irregularity or improper ingredients; stomatal: casting aluminum water mixed with air; trachoma: cast aluminum water mixed with impurities; dip sand: improper or no workpiece temperature baked shot and so on. Four, cylinder head machining difficulties: 1, plane processing the cylinder head top surface, a bottom surface and into the exhaust area planar faces are large, high precision (flatness 0.04 0.05 verticality, the position degree of 0.10), and may be the basis for all of the process, for example, the cylinder 480 Cover is. This geometric accuracy of the machine and tool adjustment is relatively high precision. Previous large flat cylinder head machining, machining with carbide blade, and with a diamond blade Danxiu Guang. Now, if the situation is good rough, all using diamond blade for processing, may well improve the surface roughness after processing. 2, high-precision machining holes cylinder head valve seat tube hole, holes, etc. tappet camshaft bore holes and the Department has with the relationship. Its dimensional accuracy, position accuracy and surface roughness requirements are extremely stringent. So these high-precision machining holes of cylinder head technology process is the core process, should be given full attention. 1, cylinder head valve seats, valve guides finishing cylinder head valve seats, valve guides with both the engine valve, so that the coaxial degree is relatively high; additional valve seat for sealing engagement with the valve cone, the roundness requirements are very high. For the processing of these parts, now 480 head breaks down as follows: Fast Forward - spindle work into - spindle restart processing valve seat cone - spindle stop and back end of the spindle distance - restart gun reaming valve guides ( QianTong) - finished processing - workers and retract - spindle pushed back. The benefit is that once positioned, processing is complete valve guides and valve seat, positioning error can reduce duplication and improve the valve guides and valve seat concentricity. In addition, the spindle after the restart, machining the valve seat when the feed direction if the radial direction along the seat, processing methods such as car seat, providing precision. If the feed direction along the axial direction of the valve seat, called countersink orBoring seat. Because the valve seat and valve guide material change in the selection process of the tool is constantly changing. Carbide inserts before gradually replaced CBN inserts, great processing efficiency and provide quality. And if there is copper powder material valve seat and valve guide, PCD inserts can also be used for processing. 2, cylinder head tappet hole bottom outlet valve guide machiningThese hole machining, although precision is relatively high, however, as long as the selected allowance, and the tool, the process basically no problem. 3, cylinder head camshaft hole machiningCamshaft cylinder head bore, the cylinder head is the longest holes in the staging process, even though the camshaft hole processing can ensure accuracy, but can not meet the requirements of the camshaft hole concentricity, it requires a finish molding. For the length of the shank is about 500mm, the arbor itself how to eliminate the impact of gravity?For the purposes of automatic line plane, generally with boring mold to eliminate the influence of the relatively large engine, there may be several boring with mold. For machining centers, now has basically been canceled boring mold, the use of self-oriented tool to eliminate the effects of gravity Arbor. Arbor structure is characterized by: the circumference of the holder, evenly arranged a blade and three guide bars. Arbor quantity is generally a long, one short.Process as follows:First by knife rod processing a camshaft hole (to the semi-finished dimension) - retraction - Long shank complete all the camshaft hole semi-intensive, finishing. 4, cylinder head machining process burr For aluminum alloy cylinder head, because it is a plastic material, processing inevitable glitches.For processing glitches, in addition to a reasonable selection of machining parameters, tool parameters, but also can improve the hardness of the workpiece material, it can weaken the processing of burrs.Now the process, mainly in the following several ways to remove burr:A nylon brush deburring, and more for the processing of large surfaces and large holes of deburring;Second, the high-pressure water deburring, used for deep-hole deburring, there are also a rotating water jet Omo or large burr hole; Third, the surface shot peening or surface: the surface used for casting burrs processing, affecting the cleanliness of the workpiece; Fourth, the spark deburring: for the more difficult to remove burrs, such as steel burrs, for irregular burr removal more difficult; five hydroxide blasting deburring: the use of hydrogen combustion pressure and high-temperature air, will be attached to the surface of the workpiece burrs eliminated, but high demand for workpiece blank, patching, crack, cold traps are likely to lead to the workpiece scrapped. 5, cylinder head cleaning Cylinder head cleaning process is one of the main auxiliary processes. Cleanliness on the head because the engine was very strict (We now head AVL cleanliness indicators: 7mg), while the cylinder head is a complex consisting of a porous cavity casting box, if not thoroughly cleaned leaving the sand and aluminum shavings from entering the engine lubrication system or cylinder, it will directly affect the work and life of the engine. Therefore, we should pay full attention to the cylinder head cleaning process.For head cleaning machine, it is now generally with jet cleaning station, the equivalent of pre-cleaning station, flip the workpiece in the tank cleaning nozzles with compressed air flow from step to achieve the effect of cleaning the workpiece thick. For assembly requirements or difficult to clean the place, generally equipped with a washing machine cleaning station vertex positioning, you can clean the parts required. But will cause the machine to increase the length inconvenience nozzle arrangement, but can not meet the needs of flexible cleaning. For head cleaning waterways as being rough casting quality is relatively large, it is also a cleaning difficult. Fifth, the typical process flow cylinder headHere we AVL cylinder head machining process, for example, to understand how the machining center machining cylinder head parts:OP10: blank feeding;OP20: rough benchmark positioning, processing cylinder head intake and exhaust side (in addition to the intake side of the hole is not working outside);OP30: benchmarking exhaust side finishing, processing the top surface of cylinder head, before and after the machining face;OP40: benchmarking exhaust side finishing, processing cylinder head top surface, the combustion chamber surface machining content; OP60: the cleaning process; OP70: head waterways, and oil leak; OP80: cylinder head valve seat and valve guide assembly (assembly room temperature); OP90: camshaft cylinder head cover, pin assembly, automatic camshaft cap bolts tightened; OP100: exhaust side finishing benchmarking, complete cylinder head top surface and the combustion chamber surface finishing (valve guides and valve seat finishing); OP110: exhaust side finishing benchmarking, complete cylinder head camshaft hole and the front and rear end finishing; OP120: Final cleaning process; OP130: gluing, pressing bowl plug, ball; OP140: leak testing machine; OP150: visual inspection; OP160: marking process; OP170: finished cutting. From the above process point of view, have been used for the machining center manufacturing technology, manufacturing technology and other more agile production line manufacturing technology now.In addition, in order to better carry out multi-species collinear production, cylinder head design, technology benchmarks are converted to the exhaust side, in order to better carry out collinear production. six, cylinder head machining note:1, cylinder head size is large, due to internal stress redistribution and deformation, will seriously affect the cylinder head machining accuracy. The general principle is that after the first surface hole, roughing and finishing try to spread in order to ensure processing stress release.2, in order to avoid surface
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