In the engine manufacturing industry, multi-variety cylinder collinear flexible production can give full play to the use value of the production line, so that one investment can produce a variety of products, thereby achieving the goal of maximizing investment returns. However, how to realize the collinear production of multi-variety cylinders under the premise of ensuring long-term stability of product quality is one of the problems faced by many domestic enterprises in the planning and design of new production lines. On the basis of fully analyzing the product characteristics, weighing the characteristics of various processing schemes, and determining the process principles, this paper deeply studies the equipment selection and process flow, and realizes the collinear production of various products by adopting a reasonable flexible manufacturing scheme.
Product characteristics and difficult analysis
Due to the extremely high processing precision requirements of this project, especially the key special characteristics, it has reached the processing level required by world-renowned excellent engine parts. For example, the honing requirement is R 3z =2.0-6.0μm, the diameter and depth of the mouth are The tolerance bands are 0 to 0.02 mm and 0 to 0.04 mm, respectively, and these characteristics directly affect the final performance of the engine.
The difficulty of this project is that there are many varieties, large batches, high processing precision requirements, and the product quality must be guaranteed to be stable for a long time in the mixed line production process. Therefore, the finishing equipment must have high flexibility and stability.
Process planning
1. Process design principles
(1) The production line should be able to meet the collinear production of four types of cylinders.
(2) To achieve the first-class technological level of similar products in China.
(3) A high-speed machining center with high production efficiency and good equipment stability and a dedicated rigid and flexible manufacturing equipment to form a hybrid production system to adapt to future product upgrades and other changes that may occur.
(4) Based on the principle of advanced technology and reasonable economy, the equipment selection meets the characteristics of advanced, reliable and mature technology, and does not blindly pursue import and excessive automation.
(5) Inductive and pneumatic measuring instruments are widely used in process testing; the main dimensions of parts are inspected on the line, and the data is statistically analyzed; according to special characteristics analysis, automatic detection tools are provided for key processes, and tools are realized. Automatic compensation.
(6) Adopting machine clamps without re-grinding tools, coated tools, CBN tools, ceramic tools, internal cooling tools, and using quick-change tool holders to implement machine-to-machine tool setting.
(7) The equipment adopts a fully enclosed protective structure, and a large-flow centralized cooling system is adopted to keep the workshop environment clean and tidy.
(8) Strengthen the auxiliary process, use high-pressure fixed-point positioning cleaning technology to clean the cylinder oil passage, inner cavity and water jacket, and equipped with special deburring equipment to remove the burrs of the cylinder oil passage and key joint surface to ensure the cleaning of the product. Degree and quality.
(9) The KBK suspension crane is used for the blank of the parts and the lower line of the finished products. The motorized roller is used for the transportation between the parts, and the power-assisted manipulator is used for the loading and unloading of the machining center parts.
(10) The machine shop uses layered air conditioners.
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