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High-speed performance is also evident in engine companies. A large number of coated carbide tools PCD and CBN are used, and the cutting speed is greatly improved. HSK chucks are also commonly used. Combine machining processes and tools to save equipment investment and reduce machining time. For example, a multi-tool with drilling, milling and threading is used to complete the drilling, chamfering and milling threads. In short, in terms of products, under the satisfactory performance, the processing technology is simple, and some processing is solved in the casting as much as possible, so that the machining allowance is small in the machining. In terms of process technology, new processes are adopted to adapt the tools and equipment to the needs of high speed and flexibility. There are also many different places in production organization and management. The structure of the company is simple. Many service departments, such as oil products, cutting fluids, cutting tools and equipment spare parts, are handled by professional companies. Personnel are motivated by group and rotation. Logistics and equipment management are also the focus, and engine manufacturing company TPM is an important part. In terms of quality, German companies place great emphasis on process quality.
Product aspects (1) Lightweight research shows that if the quality of a car can be reduced by 10%, its fuel economy can be increased by 3% to 4%, and car emissions will also be reduced. For this reason, in order to make the engine lighter, higher in speed, higher in power, and higher in durability, the best way for automobile manufacturers in various countries is to use an aluminum cylinder. Its advantages: 1 aluminum thermal conductivity is good, improve the compression ratio of the engine, is also very beneficial to improve power. The expansion ratio of the 2 cylinder block and the cylinder head is the same, which reduces the thermal stress and improves the rigidity of the joint surface of the cylinder block and the cylinder head. 3 light weight.
(2) Structure of the cylinder head structure The cylinder head is generally an integral aluminum cylinder head with a camshaft bearing hole. For the convenience of processing, the integral cylinder head is divided into two or divided into three parts. The camshaft is not placed on the cylinder head but is housed in the casing.
(3) The function of the camshaft camshaft is to control the opening and closing of the valve. The first change is that the four- and five-valve camshafts use a lightweight hollow camshaft for weight removal. The second change, conventionally, the blank of the camshaft is generally a casting or forging, which is then roughed, heat treated, and finally ground. The new camshaft manufacturing method uses a fabricated blank to assemble the prefabricated cam and related components onto a steel pipe, and fixes its axial and angular positions to increase flexibility, which is costly.
(4) Balance shaft body (Ausgleiehswellenmodul) In the three-cylinder machine, in order to reduce the vibration, the engine runs more smoothly, and a balance shaft body is added to the product. Currently, the VW Group's 1.2L four-valve engine for PoLo is equipped with a balanced shaft. Since this part can significantly balance engine vibration and improve engine operation, ZL's four-cylinder machine will be equipped with a balanced shaft body in the future.
Process tool (1) The product change causes the process change to have the aluminum cylinder of the cylinder liner. The cylinder hole of the factory in foreign countries first puts the cylinder sleeve with the zigzag surface on the surface, then casts it, and the cast iron part separates the upper plane 2~ 4mm, in order to facilitate the processing of the upper plane of the cylinder. The rough machining of the cast iron cylinder liner is completed in the blank factory, leaving a margin of lmm. In the process arrangement, the cylinder hole and the main bearing hole are placed in the back processing, and the upper and lower planes are processed in front of the four sides. Different from the previous process arrangement, the processing technology is simpler than before. After the cylinder head becomes a rectangular parallelepiped, the cylinder head processing is easier than before. Because there is no machining of the camshaft bearing bore, high-speed and flexible changes can be achieved with a dedicated simple machining center machine. After the assembled camshaft, the heat treatment and assembly of the cam are carried out by the supplier, and the semi-finished products are supplied to the manufacturer. The process is as follows: the main shaft of the camshaft - the spindle neck mill - coarse, fine grinding cam - polishing - cleaning.
(2) Three important trends. Foreign engine manufacturers have performed significantly in three important areas, mainly as follows:
First, the speed is high. High-speed machining increases productivity and reduces lead times. To achieve high-speed machining, the main steps: 1 machine tool to achieve high-speed spindle. 2HSK hydraulic chuck has high positioning accuracy and good rigidity. 3 A large number of coated carbide tools, cermet, ceramic, CBN, PCD tools. For example, a large number of high-speed machining centers are used on the cylinder head line, and the hard parts are processed. It can simplify the process, process, cost and flexibility. For example, camshaft machining, Germany's diesel engine in Hungary, used to turn and grind when machining the journal, and now use CBN tool to complete the required surface roughness, do not grind, can reduce a large investment. The third is dry processing. The advantage is that it can meet the requirements of environmental protection and reduce the total cost. For example, cylinder cylinder hole roughing, using ceramic blades without emulsion. At present, foreign countries attach great importance to the use of spray in the dry processing - quasi-dry processing.
(3) Flexible manufacturing engine manufacturing flexibility is one of the trends. In the traditional automatic line local station with CNC or machining center, the flexible processing line is called flexible automatic line FTL, which is used in Japan, mainly for families. The product of the class, in a strict sense, is also the design concept of the automatic line.
The flexible manufacturing system consisting of special machining centers is mainly used in cylinder heads and cylinders. From the perspective of production, it can be achieved from the traditional FMS system with a production capacity of 50,000 pieces/year to the output of traditional automatic lines of 200,000 pieces/year. If you want to plan a flexible flexible production line suitable for mass production, to suit the uncertainty of procurement, the design, environmental requirements and production requirements are constantly updated due to the development of new varieties. Considering these factors in a flexible production line can make an investment of more than 500,000 pieces per year more reasonable, saving about $1 to $2 billion in the next 10 years.
Since the cylinder requires less workpiece clamping times, it is mostly a casting. The materials and dimensions determine the economics of using automatic lines. The current use of mixed production lines has become a new trend. In the process, a large amount of cutting is completed on a conventional automatic line, and the front and rear end faces and sides of the cylinder are processed, and a flexible production unit is used.
(4) High efficiency From the situation of the Japanese automobile manufacturing industry, the average cutting efficiency is increased by 28% every five years, in which the cutting speed is increased by an average of 19%, the feed rate is increased by 8% on average, and the cutting efficiency is improved in recent years. The amplitude is above 30%. At present, the production cycle of the main parts of the engine has been shortened to 30 to 40 seconds. It is 50% shorter than a decade ago. For example, in the milling of gray cast iron material cylinders, the cutting speed can reach 700-1500 m/min with a high-speed machining center machine. The tool uses a CBN blade. ( auto1950 ) PCD tools are widely used in the milling of cylinder and cylinder head aluminum alloy materials. Considering that high centrifugal force will generate a large centrifugal force, the cutter body is made of high-strength aluminum alloy material. The camshaft and crankshaft are ground at high speed with a CBN grinding wheel. Hole machining of the crankshaft and camshaft, in order to improve efficiency, the use of an internal cooling carbide drill instead of the past high speed steel drill. Tapping threads also use carbide taps to increase speed, and even crankshaft tapping uses non-cutting taps. There is a trend in high-speed machining centers that use hot-mounted tool systems. In short, there is a clear trend in the engine manufacturing industry, using high-speed machining to improve efficiency.
(5) The application of the expansion process is more common. Since the expansion of the connecting rod big hole is made by the expansion process, most factories use the expansion process. There are still some problems in the application of this technology in domestic factories, mainly the labor waste rate and the link explosion generated during assembly. The foreign factories have mastered the process well, their work waste rate is 0.8%, and the explosion of the assembly is almost zero. The problem is the gap control of the support block during expansion.
(6) Combining the use of high-speed external milling on the basis of crankshaft pulling. In recent years, the machining of the crankshaft main journal and the connecting rod neck is generally carried out by the car pulling process. However, the neck line of the connecting rod is not on a center line, such as a three-cylinder or six-cylinder engine, and there is some trouble in processing. At present, there is a processing technology scheme: the spindle neck is pulled by the car, and the connecting rod neck is used for high speed outer milling. This is more flexible when machining the connecting rod neck.
(7) The new improvement of the crankshaft balancer is the unbalance quantity correction using the polar coordinate optimization high-speed drilling correction method. In the past, high-speed steel was used. The new method is to use a solid carbide drill for crankshaft drilling. There is a coolant hole in the core of the drill. This type of drill can perform large feed drilling.
(8) Laser honing of the cylinder bore. In recent years, surface laser honing processing is gradually being used. In order to achieve the surface roughness and oil storage performance of the cylinder bore at the same time, special processing technology, that is, laser honing, is required to achieve the processing requirements without affecting the cylinder bore surface. Processing quality. With laser honing, automotive engines can reduce fuel consumption, reduce emissions and reduce wear. In addition, diesel engines are widely used in cars. The diesel engine is small in size and powerful in power. When the cylinder is cast, TiC is added. In order to flush the TiC on the cylinder bore surface, the generated burrs are removed, and the surface oil storage is achieved. The high pressure liquid honing process is as follows: rough ç© + fine ç© ten high pressure liquid honing ten polishing.
(9) Crankshaft grinding machine camshafts are very popular with CBN grinding wheels for high speed grinding. At present, the machining of the crankshaft is gradually beginning to use CBN grinding wheel processing. Generally speaking, as long as the four-cylinder crankshaft is a change in lift, the process route is still better in the past: the main journal has multiple grinding wheels, and the connecting rod neck uses double grinding wheels. If you want to machine four-cylinder, five-cylinder and six-cylinder crankshafts, you must use CBN single or double grinding wheels to grind the crankshaft, so that the flexibility is good, and the grinding wheel can process 600-800 pieces every time it is finished.
Organization and production management (1) Simple structure The structure of the engine factory is just a productive factory compared to the previous factory, especially in overseas factories. Service work is left to the professional department. For example, Tool-Management was introduced in the United States in the 1990s and began with the US-based Saturn project 16 years ago. At that time, the tool management was mainly logistics. The tool was relatively simple. There was no finishing tool. Later, it gradually developed into a complete system. Even in the beginning of the new project, tool management participated in the project support. Implemented in Germany and Europe in the late 1990s, although it is used less, it is a potential management model. From the scope, there will be more and more enterprises, especially the automotive industry. At present, the OPel factory in Hungary, the Volkswagen factory in Poland, and the GM in Shanghai are carrying out tool management. Reduced sharpening, warehouse management, procurement, and technical management personnel, making the organization simple.
(2) Cost Center In the increasingly fierce competition of the automobile industry, reducing the cost of products has become an important strategy for competition among auto manufacturers. Promoting cost reduction as a hard indicator is the trend of the global automotive industry. The engine plant is no exception, and cost reduction is an important goal. Generally speaking, each workshop establishes a cost center. The main indicators are work waste, material waste, personnel expenses, tool accessories costs, and equipment depreciation.
(3) TPM and personnel incentives The engine plant equipment is relatively complex, high precision, and has a certain technical content. After the completion of the new production line planning, an important task is TPM. First of all, the specific implementation plan is proposed. Each line has a responsible person, and strengthens the inspection and professional inspection. Propose a suitable solution for a specific machine tool. Not to do some superficial articles, based on simple and clear ideas, followed by down-to-earth implementation. Use some of the right people, not highly educated employees, with a focus on on-the-job training. In order to encourage employees, the vacation system is actively adopted, and a one-year vacation plan for the entire production line is posted on the production line. The maintenance and operation workers will form a group, and in order to solve the monotonous production, new problems will arise, and post rotation will be carried out after a period of time.
(4) Quality Management Any engine factory places quality at the core of the company's strategy. Quality management is one of the most important “internal strengths†of development. Concessions in quality are by no means an option. Any concession may threaten the survival of the company. Only those companies that are committed to quality improvement can succeed and profit. Engine plants improve the quality of the key means to determine the quality objectives, the highest level of participation. The use of zero-defect production as a core process to strengthen quality process control. Mobilize all employees to participate, solve problems by workshop workers themselves, and set up Qc team to improve quality.
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New trends in automotive engine manufacturing (including grinding wheel grinding)
Abstract Since the beginning of the 21st century, the engine manufacturing industry has undergone a series of changes in terms of products, manufacturing processes, cutting tools, and production management. It is different from the previous engine manufacturers. The trend of lightweighting in products is obvious, and the cylinder parts replace the cast iron with aluminum alloy...
Since the beginning of the 21st century, the engine manufacturing industry has undergone a series of changes in terms of products, manufacturing processes, tools, and production management, which are different from those of the past engine manufacturers. The trend of light weight in the product is obvious, and the cylinder parts replace the cast iron with aluminum alloy. The cylinder head product is simple and does not use the form of the previous overhead camshaft, making the cylinder head processing easier. Continuously optimized in the process, the crankshaft has developed a new high-speed outer milling process in addition to the one-car pull technology, making it more flexible. The camshaft is packaged rather than monolithic, making it easy to machine and flexible. The application of the expansion and contraction process of the connecting rod is increasing and mature.