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Engine parts in the engine block is a more complex structure of spare parts box, its high precision, processing, complex process, and the processing quality will affect the overall performance engine, so it has become the engine manufacturer's focus parts one. 1. Technical Characteristics of the engine cylinder block 10803
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Engine block is the basic engine parts and skeleton, while the engine when the general assembly of the base components. Cylinder's role is supporting and ensuring the piston, connecting rod, crankshaft and other moving parts work, the exact location; to ensure the engine ventilation, cooling and lubrication; to provide a variety of auxiliary systems, components and engine installation. 1.1 Technical Characteristics Cylinder cast for a whole structure, and its upper part 4 cylinder mounting hole; cylinder standard cylinder is pided into upper and lower pisions into two parts; cylinder to the rear of the front-side arrangement of the previous three coaxial mounting hole of the camshaft and the idler axle hole. Cylinder process features are: the structure of complex shape; processing plane, more than holes; uneven wall thickness and stiffness is low; processing of high precision typical of box-type processing part. The main processing of the surface of cylinder block top surface, the main bearing side, cylinder bore, the main and camshaft bearing bore holes and so on, they will directly affect the machining accuracy of the engine assembly precision and performance, mainly rely on precision equipment, industrial fixtures reliability and processing technology to ensure the reasonableness. 2. Engine block process design principles and the basis for
Technology program is the preparation of the master process is to process planning and key process equipment design guidance documents. The correct process of program design, facilitate the systematic application of new scientific and technological achievements and advanced production experience, to ensure product quality, improve working conditions, and improve process technology and process management level. 2.1 Process design principles
Design Technology program should be to ensure product quality at the same time, give full consideration to the production cycle, cost and environmental protection; based on the enterprises ability to actively adopt advanced process technology and equipment, and constantly enhance their level of technology. Engine block machining process design should follow the following basic principles:
(1) The selection of processing equipment, processing equipment, the principle of selection adopted the principle of combining rigid-flexible, processing each horizontal machining center is located mainly small operations with vertical machining center, the key process a crank hole, cylinder hole, balancer shaft hole High-speed processing of high-precision horizontal machining center, an upper and lower non-critical processes before and after the four-dimensional high-efficiency rough milling and have a certain adjustment range of special machine processing;
(2) focus on a key process in principle process the body cylinder bore, crankshaft hole, Balance Shaft hole surface finishing and the combination of precision milling cylinder head, using a process focused on a setup program to complete all processing elements in order to ensure product accuracy The key quality processes to meet the cylinder capacity and the relevant technical requirements; (3) All fixtures are used hydraulic clamp, clamping components, hydraulic pumps and hydraulic control components used in Germany or the United States producing high quality and reliable components; (4) The whole line used in all wet processing, using standalone BTA, high-precision machining processes critical horizontal machining center with constant cooling and to install high-precision high-voltage double-circuit band-pass fine filtration system, all with high-pressure processing center in the cold. According to the technological characteristics of automobile engine cylinder block and the production mandate, the engine block machining automatic production line is composed of horizontal machining center CWK500 and CWK500D machining centers, special milling / boring machine, vertical machining centers matec-30L and other appliances. (1) top and bottom, and tile covered only the combination of aperture rough milling machine dedicated to this machine to double-sided horizontal milling machine, using moving table driven parts, machine tools imported Siemens S7-200PLC system control, machine control cabinet set up an independent, cutting automate the process is completed and two kinds of automatic and adjust the state; (2) high-speed horizontal machining center machining center can be realized CWK500 the maximum flow of wet processing, but because of equipment, automatic BTA treatment system through the built-in tray under the wide-type chip conveyor and the completion of the machining center can be dry processing; machine tool spindle speed 6000r/min, rapid feeding speed 38m/min; (3) The combination of front and rear face rough milling machine tool using hydraulic transmission; control system imported Siemens S7-200PLC system control, machine tools have a certain flexibility; (4) The special machine TXK1500 this machine vertical machining center by the modification of shape, with vertical machining center features and performance, this machine has high strength, high wear-resistant, high stability, high accuracy, high-profile etc.; (5) high-speed vertical machining center matec-30L of the machining center spindle high speed 9000r/min. Control system uses Siemens SINUMERIK840D control system; (6) high-speed horizontal machining center spindle CWK500D highest speed 15000r/min. 2.2 Process design basis