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外文資料
The crank processes specification and development direction
The crank processes specification
The crank specification is very high, its machine-finishing technological process different and the crank complex degree has the very big difference along with the production guiding principle, but includes following several main stages generally: Localization datum processing; Thick, lathe finishing and rough grinding each host neck and other outer annuluses; Che Lianjing; Drills the oil hole; Correct grinding each host neck and other outer annuluses; Correct grinding Lian Jing; Big, capitellum and key slot processing; Journal surface treatment; Transient equilibrium; Super finishing various journals.
May see, the main neck or Lian Jing the turning working procedure all separates with the grinding working procedure, is often middle arrangement some different machined surfaces or the heterogeneity working procedure. After the rough machining can have the distortion, therefore the normal force reduces gradually; Because simultaneously thick, the precision work working procedure carries on separately before, the latter working procedure has the possibility to eliminate the working procedure error, finally obtains the very high precision and the very low roughness. Thick, the precision work separates, and arranges the alignment working procedure behind the cutting force big working procedure, guarantees the processing precision.
In order to reduce the distortion which the cutting force causes, guaranteed when precision work precision request, correct grinding various journals, uses the single grinding wheel in turn grinding generally.
The journal processing requests high, the main neck and the neck uses continually processes many times.
Crank machining development direction
Along with our country numerical control engine bed unceasing increase, the crank rough machining will be widespread uses in the numerical control lathe, the numerical control the milling machine, the numerical control vehicle broaching machine and so on the advanced equipment to the main journal, the connecting rod journal carries on the numerical control turning, in the milling, the vehicle - broaching processing, by will effectively reduce the amount of deformity which the crank will process. The crank precision work will be widespread uses the CNC control the crankshaft grinding to carry on the correct grinding processing to its journal, this kind of grinder will provide grinding wheel automatic function requests and so on transient equilibrium installment, center rest automatic tracking unit, automatic survey, self-compensating system, grinding wheel automatic conditioning, permanent link speed, will guarantee the grinding quality the stability.
In order to satisfy the processing request which the crank enhances day by day, set the very high request to the crankshaft grinding. The modern crankshaft grinding except must have the very high static state, the dynamic rigidity and outside the very high processing precision, but also requests to have the very high grinding efficiency and more flexibilities. In recent years, requested the crankshaft grinding to have the stable processing precision, for this, had stipulated to the crankshaft grinding process capability coefficient Cp≥1.67, this meant requested the crankshaft grinding the actual processing common difference to have the common difference which assigned compared to the crank small one half. Along with the modern actuation and the control technology, the survey control, CBN (cubic boron nitride) the grinding wheel and the advanced engine bed part application, for the crankshaft grinding high accuracy, the highly effective abrasive machining has created the condition. One kind calls it the connecting rod neck follow-up grinding craft. Has manifested these new technical synthesis application concrete achievement. This kind of follow-up grinding craft may obviously enhance the crank connecting rod neck the grinding efficiency, the processing precision and the processing flexibility. When carries on the follow-up grinding to the connecting rod neck, the crank take the main journal as the spool thread carries on revolving, and clamps the grinding all connecting rod neck in an attire. In the grinding process, the wheelhead realization reciprocation swing feed, tracks the biased rotation connecting rod neck to carry on the abrasive machining. Must realize the follow-up grinding, X axis besides must have the high dynamic performance, but also must have the enough tracking accuracy, guarantees the shape common difference which the connecting rod neck requests. The CBN grinding wheel application realizes the connecting rod neck follow-up grinding important condition. Because the CBN grinding wheel resistance to wear is high, in the grinding process medium plain emery wheel diameter is nearly invariable, a conditioning may the grinding 600~800 cranks. The CBN grinding wheel also may use the very high grinding speed, may use generally on the crankshaft grinding reaches as high as the 120~140m/s grinding speed, the grinding efficiency is very high.
Connecting rod processing and trend of development
Connecting rod processing method
The connecting rod decomposes (also called connecting rod breaks) the technical principle uses the material break theory, first artificial has the whole forging connecting rod semi finished materials big end of hole the fissure, forms the initial break source, then expands with the specific method control fissure, achieved the connecting rod The decomposition processing process enable the decomposition the connecting rod cap, the pole adjoining plane to have the complete meshing jig-saw patterned structure, guaranteed the adjoining plane precise docking, tallies, does not need to carry on the adjoining plane again the processing, simultaneously simplified the connecting rod bolt hole structural design and the whole processing craft, has the processing working procedure few, the economical precision work equipment, the nodal wood energy conservation, the product quality high, the production cost low status merit. Main body and the connecting rod cap separate goal.
Trend of development
At present, the drop for and the die casting connecting rod host, the important status, are facing the powder to forge the steel connecting rod and a powder agglutination steel connecting rod forming craft challenge. Speaking of the domestic present situation, although the powder metallurgy forging industry had certain development, but must provide the mass and the high grade powder metallurgy forging is not mature. Moreover involves the equipment to renew, aspect expense questions and so on technical change, in next one, in long time, domestically produced connecting rod production also by drop forging craft primarily.
The connecting rod is one of internal combustion engine main spare parts, its reducing socket two sizes and the shape position errors have many requests, for example: Diameter, roundness, cylindricity, center distance, parallelism, hole and end surface verticality and so on. How does these erroneous project produce the scene in the workshop to examine, always is in the internal combustion engine profession a quite difficult question.
In the connecting rod production, domestic mainly has following several examination method at present: With the spindle survey, namely puts on the spindle in connecting rod two, with the aid of in V shape block, plate, dial guage survey. Because the spindle needs to load and unload, therefore between the hole axis has the gap, the measuring accuracy is very low.
中文翻譯
曲軸加工的技術(shù)要求及發(fā)展方向
曲軸加工的技術(shù)要求
曲軸的技術(shù)要求是很高的，其機(jī)械加工工藝過程隨生產(chǎn)綱領(lǐng)的不同和曲軸的復(fù)雜程度而有很大的區(qū)別，但一般均包括以下幾個(gè)主要階段：定位基準(zhǔn)的加工；粗、精車和粗磨各主頸及其它外圓；車連頸；鉆油孔；精磨各主頸及其他外圓；精磨連頸；大、小頭及鍵槽加工；軸頸表面處理；動(dòng)平衡；超精加工各軸頸。
可以看出，主頸或連頸的車削工序都與磨削工序分開，往往中間安排一些不同的加工面或不同性質(zhì)的工序。粗加工后會發(fā)生變形，因此常把粗、精加工分開，并在切削力較大的工序后面安排校直工序，以保證加工精度。
為了減小切削力所引起的變形，保證精加工的精度要求，精磨各軸頸時(shí)，一般采用單砂輪依次磨削。
軸頸的加工要求高，主頸和連頸采用多次加工，使加工余量越來越小，切削力逐漸降低；同時(shí)由于粗、精加工工序分開進(jìn)行，后工序就有可能消除前工序的誤差，最終獲得很高的精度和很低的粗糙度。
曲軸機(jī)加工發(fā)展方向
隨著我國數(shù)控機(jī)床的不斷增加，曲軸粗加工將廣泛采用數(shù)控車床、數(shù)控內(nèi)銑床、數(shù)控車?yán)驳认冗M(jìn)設(shè)備對主軸頸、連桿軸頸進(jìn)行數(shù)控車削、內(nèi)銑削、車-拉削加工，以有效減少曲軸加工的變形量。曲軸精加工將廣泛采用CNC控制的曲軸磨床對其軸頸進(jìn)行精磨加工，此種磨床將配備砂輪自動(dòng)動(dòng)平衡裝置、中心架自動(dòng)跟蹤裝置、自動(dòng)測量、自動(dòng)補(bǔ)償裝置、砂輪自動(dòng)修整、恒線速度等功能要求，以保證磨削質(zhì)量的穩(wěn)定。
為滿足曲軸日益提高的加工要求，對曲軸磨床提出了很高的要求?，F(xiàn)代曲軸磨床除了要有很高的靜態(tài)、動(dòng)態(tài)剛度和很高的加工精度外，還要求有很高的磨削效率和更多的柔性。近年來，更要求曲軸磨床具有穩(wěn)定的加工精度，為此，對曲軸磨床的工序能力系數(shù)規(guī)定了Cp≥1.67，這意味著要求曲軸磨床的實(shí)際加工公差要比曲軸給定的公差小一半。隨著現(xiàn)代驅(qū)動(dòng)和控制技術(shù)、測量控制、CBN（立方氮化硼）砂輪和先進(jìn)的機(jī)床部件的應(yīng)用，為曲軸磨床的高精度、高效磨削加工創(chuàng)造了條件。一種稱之為連桿頸隨動(dòng)磨削的工藝。正是體現(xiàn)了這些新技術(shù)綜合應(yīng)用的具體成果。這種隨動(dòng)磨削工藝可顯著地提高曲軸連桿頸的磨削效率、加工精度和加工柔性。在對連桿頸進(jìn)行隨動(dòng)磨削時(shí)，曲軸以主軸頸為軸線進(jìn)行旋轉(zhuǎn)，并在一次裝夾下磨削所有連桿頸。在磨削過程中，磨頭實(shí)現(xiàn)往復(fù)擺動(dòng)進(jìn)給，跟蹤著偏心回轉(zhuǎn)的連桿頸進(jìn)行磨削加工。要實(shí)現(xiàn)隨動(dòng)磨削，X軸除了必須具有高的動(dòng)態(tài)性能外，還必須具有足夠的跟蹤精度，以確保連桿頸所要求的形狀公差。CBN砂輪的應(yīng)用是實(shí)現(xiàn)連桿頸隨動(dòng)磨削的重要條件。由于CBN砂輪耐磨性高，在磨削過程中砂輪的直徑幾乎是不變的，一次修整可磨削600～800條曲軸。CBN砂輪還可以采用很高的磨削速度，在曲軸磨床上一般可采用高達(dá)120～140m/s的磨削速度，磨削效率很高。
連桿的加工方法和發(fā)展
連桿的加工方法
連桿裂解（也稱連桿脹斷）技術(shù)的原理就是利用材料斷裂理論，首先將整體鍛造的連桿毛坯大頭孔人為產(chǎn)生裂痕，形成初始斷裂源，然后用特定方法控制裂痕擴(kuò)展，達(dá)到連桿本體與連桿蓋分離的目的。裂解加工過程使裂解的連桿蓋、桿接合面具有完全嚙合的犬牙交錯(cuò)結(jié)構(gòu)，以保證接合面精確相接、吻合，無需再進(jìn)行接合面的加工，同時(shí)簡化了連桿螺栓孔的結(jié)構(gòu)設(shè)計(jì)和整體加工工藝，具有加工工序少、節(jié)省精加工設(shè)備、節(jié)材節(jié)能、產(chǎn)品質(zhì)量高、生產(chǎn)成本低等優(yōu)點(diǎn)。
發(fā)展趨勢
目前,模鍛和模鑄連桿的主、重要地位,正面臨著粉末鑄造鋼連桿和粉末一次燒結(jié)鋼連桿成型工藝的挑戰(zhàn)。就國內(nèi)現(xiàn)狀而言,粉末冶金鍛造工業(yè)雖然有了一定的發(fā)展,但要提供大批量和高質(zhì)量的粉末冶金鍛件還不成熟。而且涉及設(shè)備更新、技術(shù)改進(jìn)等方面費(fèi)用問題,在今后一個(gè)比較長的時(shí)間內(nèi),國產(chǎn)連桿生產(chǎn)還將一模鍛工藝為主。
連桿是往復(fù)泵的主要零部件之一,他的大小頭二孔的尺寸和形位誤差有多項(xiàng)要求,例如:直徑、圓度、柱度、心距、行度、與端面的垂直度等。這些誤差項(xiàng)目在車間生產(chǎn)現(xiàn)場如何檢測,一直是內(nèi)燃機(jī)行業(yè)中一個(gè)比較困難的問題。
在連桿的生產(chǎn)中，目前國內(nèi)主要有以下幾種檢測方法：用心軸測量，即在連桿二孔中穿上心軸，借助與V形塊、平板、百分表測量。因?yàn)樾妮S需要裝卸，所以孔軸之間有間隙，測量精度很低。