Technological map for the restoration of a part. Maintenance flow chart: simple things to achieve success. Advantages of implementing technological maps

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Introduction

1. General position

2.2 Selection of technological bases

2.5 Calculation of processing modes

Conclusion

Literature

Introduction

valve engine repair defect

In the process of restoring a part, it is possible not only to reduce the cost of machine repair, but also in many cases to improve its quality, since many of the restoration methods significantly strengthen the restored surfaces and increase their wear resistance.

Car repairs are of great economic importance. The main sources of economic efficiency of car repairs are the use of the residual life of their parts. About 70...75% of car parts that have completed their service life before the first repair have a residual life and can be reused either without repair or after minor repairs.

Improving the quality of machine repair while simultaneously reducing its cost is the main problem of the repair industry. In the structure of the cost of major repairs of machines, 60...70% of the costs fall on the purchase of spare parts, which, even in market conditions, remain scarce when prices rise. The main way to reduce the cost of machine repair is to reduce the cost of spare parts. This can be partially achieved through careful and competent disassembly of machines and defect detection of parts. However, the main reserve is the restoration and reuse of worn parts, because restoration of worn parts does not exceed 20...60% of the price of a new part. In addition, restoration of parts is one of the main ways to save material - raw materials and energy resources, solving environmental problems, since the costs of energy, metals and other materials are 25...30 times less than the costs of manufacturing new parts. When remelting worn parts, up to 30% of the metal is also irretrievably lost

With long-term operation, cars reach a state where the costs of money and labor associated with maintaining them in working condition in the conditions of road transport operations become greater than the profit they bring in operation. This technical condition of the vehicles is considered to be at its limit, and they are sent for major repairs (CR). The task of the Kyrgyz Republic is to restore the vehicle’s lost performance and service life to a level that is new or close to it at optimal cost.

1. General Provisions

1.1 Functional purpose, technical characteristics and operating conditions of the part

The valve is the main component of the engine gas distribution mechanism. The valves serve for periodic opening and closing of the intake and exhaust ports; they are located in the cylinder head obliquely in one row. The inlet valve is made of chromium-nickel-molybdenum steel. The functioning of the object being repaired - the camshaft cam runs into the pusher, the pusher moves the rod 19 which in turn moves the rocker arm 20 which, with the help of the striker, moves the valve 5. The valves operate in the maximum temperature zone ranging from -30 to +180 °C. The permissible seat chamfer angle should be within 44º-45º-45º; changing this angle will lead to a decrease in pressure in the cylinder and unstable engine operation.

1.2 Production program for repaired products

The annual production volume of parts is determined by the formula:

P = P sb · n · K r;

Where Psb is the annual output of the unit (assembly unit), pcs;

n - number of parts of a given name in the unit (assembly unit), pcs.;

K p - part repair coefficient, showing which part of the parts requires repair (K p = 0.8)

P = 4000 · 8 · 0.8 = 25600 pcs. (1.1)

Based on the annual program for the production of units, quarterly, monthly and daily tasks are determined. The type of production is determined approximately based on the mass of parts and the production program of the unit (assembly unit) using Table 1.1.

Table 1.1 - Dependence of the type of production on the volume of production and weight of the part

Weight of the part,	Type of production
	Single	Small-scale	Medium production	Large-scale	Mass

Because the weight of the part is less than 1 kg, and the annual production volume of parts is 25,600 pieces, then the type of production is medium-batch.

The type of production determines the form of its organization, fundamental decisions in the design of technological processes, the means of technological equipment used, etc.

2. Analysis of part defects and requirements for the repaired part

The student receives information regarding defects in the part, first of all, from the technical conditions for repairs given in the defect cards. Cards contain: name and part number; its material; quality of the surface layer of working surfaces; list of possible defects; sketch of the part indicating the location of defects; methods and means of detecting defects; dimensions of the part according to the working drawing and permissible dimensions (for wear); recommended methods for eliminating defects.

A map of technical conditions for defect detection should be included in the PP. It is necessary to identify which part defects can be repaired. Parts with irreparable defects cannot be restored.

Using the working drawing of the part and information obtained from the technical specifications card for defect detection, you should draw a repair drawing of the part, guided by GOST 2.604-2000 “ESKD. Repair drawings. General requirements".

The repair drawing shows only those views, sections and sections that are necessary to repair the part (assembly unit). Surfaces to be restored are painted with a solid thick line, the rest - with a solid thin line. Maximum deviations of linear dimensions are indicated, as a rule, by numerical values, for example 018+o,1 or statutory designations, followed by their numerical values in parentheses.

For products that cannot be separated during repair (permanent connections made by riveting, welding, etc.), it is allowed not to draw drawings for individual parts. Instructions for the repair of such products are given on a repair assembly drawing, which includes the parts being repaired, with the addition of images and data explaining the essence (content) of the repair.

In the repair drawing of a part repaired by welding, soldering, metal coating, etc., it is recommended to highlight the corresponding section of the part to be repaired.

When repairing parts by surfacing, filling (using welding, soldering, etc.), the repair drawing indicates the name, brand, dimensions of the material used in the repair, as well as the designation of the standard for the material. If, when repairing a part, a worn part is removed and replaced with a new one (additional repair part), then the removed part is depicted as a dash-dot line with two dots. The new part of the part (additional repair part) is made on an independent repair drawing.

Categorical and fitting repair dimensions of the part, as well as the dimensions of the part being repaired by removing the minimum allowance, are marked with letters, and their numerical values and other data are indicated on the shelves of the leader lines or in the table.

To determine the method (type) of repair, the corresponding technological instructions are placed on the repair drawings.

2.1 Selecting methods for eliminating part defects

When choosing rational ways to eliminate defects in a part, we use the appendices to the guidelines for completing course work. Expedient restoration methods are established based on the structural and technological characteristics of the part.

These include the type of base material of the part, the type of surface to be restored, coating material, the maximum (minimum) permissible diameter of the restored surface (external), the minimum permissible diameter of the restored surface (internal), the minimum thickness (depth) of the build-up (hardening), the maximum thickness (depth) ) building up (hardening), mating or fitting the surface being restored, the type of load on the surface being restored. Taking into account the range of representative parts recommended for restoration in one way or another, we select a number of alternative methods for restoring the part being repaired.

We evaluate the selected methods according to the physical and mechanical properties of the parts: wear resistance coefficient, endurance coefficient, adhesion coefficient, durability coefficient, microhardness. The final choice of restoration methods is made based on the technical and economic indicators of each method: specific material consumption, specific labor intensity of building up, specific labor intensity of preparatory and final processing, specific total labor intensity, process productivity coefficient, specific cost of restoration, technical and economic assessment indicator, specific energy intensity.

1 Mechanical processing: processing to repair size, installation of additional repair parts, processing until signs of wear are removed and giving the correct geometric shape.

2 Plastic deformation: drawing, drawing, straightening, mechanical expansion, hydrothermal expansion, electrohydraulic expansion, rolling, mechanical compression, thermoplastic compression, upsetting, extrusion, knurling, electromechanical upsetting.

3 Application of polymer materials: spraying (gas-flame, in a fluidized bed), crimping, injection molding, application with a spatula, roller, brush.

5 Manual welding and surfacing: gas, arc, argon arc, forge, plasma, thermite, contact.

6 Galvanic and chemical coatings: direct current ironing, periodic current ironing, flow ironing, local ironing, chrome plating, flow chrome plating (jet), copper plating, inking, application of alloys, application of composite coatings, electrocontact application, galvanomechanical method, chemical nickel plating.

We choose a method for restoring the diametrical size of the valve stem.

We determine the design and technological characteristics of the valve: material - steel 40Х10С2М; type of surface to be restored - external cylindrical, minimum permissible diameter of the surface to be restored - 9 mm; minimum extension thickness 1.02 mm; type of interface of the restored surface

Movable; type of load on the restored surface - dynamic.

Based on design and technological indicators, the priority of restoration methods is determined (in accordance with the application code).

Considering that the valve is one of the main parts that limit the overhaul life of the engine, the level of physical and mechanical properties that must be ensured when restoring the valve stem is determined:

1 wear resistance factor? 0.8;

2 endurance factor? 0.8;

3 coefficient of adhesion? 0.8;

4 durability factor? 0.8;

5 microhardness? 6000 MPa.

The above properties can be achieved in the following ways: (14, 14A, 15, 15A, 16).

For the convenience of comparing the technical and economic indicators of alternative restoration methods, we summarize the relevant data in Table 1.2.

Table 2.1 - Technical and economic indicators of alternative methods for restoring the valve stem

Taking into account the shortcomings of restoration methods, a rational method of restoration is ironing (code 15).

2.2 Selection of technological bases

The choice of technological bases largely determines the accuracy of obtaining the linear and angular dimensions of the part during the repair process. When choosing technological bases, they are guided by the following provisions:

as technological bases for repairs, it is recommended to use surfaces (axes) that served as technological bases in the manufacture of the part and do not perceive significant impacts during operation;

other things being equal, smaller errors occur when the same bases are used in all operations, i.e. when the principle of unity of bases is observed;

It is advisable to combine the technological bases with the design bases of the designed part, i.e. use the principle of combining bases;

surfaces used as technological bases in finishing operations must be of the greatest accuracy;

If the part being repaired does not have reliable technological bases, it is possible to create artificial technological bases by including in the technological process additional operations in which these bases are processed.

The choice of technological bases when repairing a part is accompanied by the calculation of alignment errors є (base misalignment errors), which is the basis for justifying the selected part installation scheme. The installation scheme is considered acceptable if the production error є у, equal to the sum of the basing error є and the error of the technological system є tc, does not exceed the tolerance T for the size maintained during the technological transition or operation being performed, i.e.

When performing the last technological transition in the processing of surfaces that are boundaries of any size, the production error e y should not exceed the tolerance value T indicated on the repair drawing.

The valve axis is taken as the base surface.

2.3 Route technological process for repairing a part

The technological process for repairing a part is developed based on the need to eliminate all defects in the part, or part of them, if the part is complex and the number of defects to be eliminated is large.

At the beginning of the technological process, we carry out preparatory operations: cleaning, degreasing, straightening and restoration of base surfaces. Then we build up the worn surfaces. In this case, first of all, operations related to heating the part to a high temperature are performed. If necessary, parts are subjected to secondary editing. After the extension, we perform mechanical processing operations on the repaired part.

We carry out control operations at the end of the technological process of repairing a part and after performing the most critical operations.

The choice of technological equipment largely depends on the type of production. Since we have mass production, we use universal machines.

One of the criteria for choosing a technological process route is an analysis of the accuracy of the repair, in accordance with which a route is accepted for implementation that ensures the receipt of a part with the specified quality (accuracy) parameters.

Table 2.2 - Technological route for valve restoration

operations	Name and content of the operation	Equipment

	Rinse and clean the valve from dirt	Washing tub
	Defective Identify wear of the valve stem and working surface of the valve chamfer	Magnetoelectric flaw detector
	surfacing Weld the working surface valve chamfers	Installation for automatic surfacing
	Grinding Grind the valve stem away from taper	Cylindrical grinding machine
	Grinding Sand the work surface valve chamfers	Cylindrical grinding machine
	Galvanic Increase valve stem diameter by galvanic ironing	Galvanic bath
	Grinding Grind valve stem	Cylindrical grinding shafting machine
	Polishing Polish the work surface valve chamfers	Lathe
	Polishing Polish the valve stem	Lathe
	Wash and clean the valve from dirt	Washing tub

2.4 Technological operations for repairing a part

The structure of operations and the sequence of transitions are closely related to the choice of technological equipment. Technological equipment includes technological equipment, technological equipment, as well as means of mechanization and automation of production processes.

The choice of technological equipment depends on the design features, dimensions and accuracy of the parts being repaired, the technological capabilities of the equipment and the economic feasibility of its use.

When choosing devices, we are guided by standards for devices and their parts, albums of typical device designs and reference books. When choosing the type and design of a cutting tool, we take into account the processing method, type of machine, dimensions, configuration, material of the workpiece, and quality characteristics of the part. We pay special attention to the choice of material for the cutting part of the tool. In parallel with choosing a cutting tool, we select an auxiliary tool. When choosing cutting and auxiliary tools, we give preference to standard tools.

We select methods and means of control during the repair process at the stage of analysis and development of technical requirements for the part being repaired.

For clarity, the selected equipment, tools, materials and equipment are presented in the form of a statement.

Table 2.3 - Summary list of equipment

		Name	Name and model	Power,

Operations	Equipment
		surfacing	Surfacing installation
		Grinding	Sianok grinding 3151
		Grinding	Grinding machine PT-823
		Galvanic	Ironing bath
		Grinding	Grinding machine 3151

Table 2.4 - Summary list of fixtures and auxiliary tools

	Name	Name	Designation, standard number

Operations	Accessories and auxiliary tools
	surfacing	Center persistent	7100-0009 GOST
	Grinding		7100-0009 GOST
	Grinding	Self-centering chuck	7100-0009 GOST
	Galvanic
	Grinding		7100-0009 GOST

Table 2.5 - Summary list of materials

The allowance for processing the surfaces of repaired parts can be assigned using reference tables or calculated using the calculation and analytical method. The calculated value is the minimum allowance for processing, sufficient to eliminate errors or defects in the surface layer obtained during the previous transition or operation during the transition being performed, and to compensate for errors that arise during the transition being performed.

Currently, there is not a sufficient amount of statistical data necessary to calculate allowances in the case of restoration of parts using various methods, therefore we assign the appropriate allowances using tabular data.

2.5 Calculation of processing modes

The method of assigning and calculating cutting modes is used in individual, small-scale and mass production. Cutting modes are selected in the following order.

Having studied the working drawing of the part and the specific workpiece element being processed, the length of the tool’s working stroke is determined. The cutting tool and its durability are selected, taking into account the properties of the material being processed, the accuracy of processing, the rigidity of the AIDS system, the amount of allowance, etc.

Using reference literature, find the cutting depth t mm. We must strive to ensure that the cutting depth is equal to the machining allowance, i.e.:

If for technological reasons (processing accuracy, surface roughness, etc.) such a ratio cannot be achieved, then in the first pass the cutting depth should be ti=(0.8...0.9) z, in the second pass t2= (0.2...0.1)z.

Then select the feed s mm. To obtain maximum productivity, they strive to use the highest feed of the machine, taking into account the specified accuracy and surface roughness after processing, the rigidity of the AIDS system and the material of the cutting tool.

Knowing t and s for a specific operation, a specific tool, material of the workpiece and processing conditions, the cutting speed v is selected or calculated. If the tool is sharpened with diamond wheels, then the resulting calculated cutting speed must be multiplied by a correction factor. Having the cutting speed, determine the estimated rotation speed of the machine spindle or the number of double strokes of the table and cutter. By checking the obtained value na with the machine’s passport data, the actual spindle rotation speed nf is determined as close as possible to the calculated one. Having determined the cutting force Рр from the reference data, the effective cutting power Na is calculated. N value uh must be less than or equal to the power of the machine’s electric motor, i.e. N uh < NdV. In this case, processing of the part is possible.

Let us determine Tpc.k for the operation of surfacing the end surface of the subgear of the D-37 engine pump.

Initial data: Valve material Steel 40Х10С2М; working surface diameter 40 mm.

We perform surfacing using OZN-250U wire; wire diameter 2 mm.

Lot of parts - 8 pieces.

Cross-sectional area

where r = 2 mm - wire radius;

Weld length

where F is the cross-sectional area of the seam, ;

L - seam length, mm;

g - density of the deposited metal, ;

k - metal spattering coefficient (k=0.9);

dн - melting coefficient, ;

I - welding current strength, A;

kc - coefficient taking into account the complexity of the work;

Auxiliary

Additional time

TD=0.05·(To+TV)=0.05·(0.7+1.3)=0.1 min, (2.4)

Piece-calculated time for surfacing one working surface of a valve chamfer

where Tпз - preparatory and final time, 10 minutes;

nn - number of parts in the batch

Let us determine the time standards for grinding work on the valve stem and the working surface of the valve chamfer

Major grinding time

where Spr - longitudinal feed, mm/rev;

Li is the length of the machined surface, taking into account the incision and grinding run, mm.

To1.2=4.9, min;

To3=6, min;

Additional time

TD1.2=0.27, min

TD3=0.4, min

The individual calculation time for grinding the valve stem and valve chamfer will be determined

1.2=7.15, min;

Let us determine the time standards for restoring the valve stem by spraying.

Main time

where h is the thickness of the coating layer, mm;

g - density of the deposited metal, g/cm3;

h - current output, %;

c - electrochemical element, g/(A*h).

The auxiliary time for loading and unloading parts into the main bath and unloading from the main bath will be 0.18 minutes.

The operational final time will be 6.39 minutes.

Piece-calculation time

where 1.12 is the coefficient taking into account the preparatory final time and extra time;

K - coefficient taking into account the use of equipment;

n - number of parts simultaneously immersed in the bath, 8 pcs.

3. Technological documentation

Technological documentation includes technological maps, drawings of devices, special tools. The most important document is the technological map. There are three levels of detail in the description of technological processes: route, operational and route-operational. Route and operational flow charts are used accordingly. The route map contains a description of all technological operations in the sequence of their execution.

An operational card for machining a part contains data about the part being processed, the workpiece, the number and name of operations and transitions, the equipment used, devices, tools, cutting modes, machine and piece time, and the type of work. In the operational description of a technological process, a complete description of all technological operations is drawn up in the sequence of their execution, indicating transitions and technological modes, and a technological map and a route map are developed for each operation. In the route-operational description, technological operations are briefly indicated in the route map in the sequence of their execution with a full description of individual, more important operations in the operational maps.

Documents on technological processes for repairing products are made taking into account the requirements of recommendations R 50-60-88 “ESTD. Rules for preparing documents for technological repair processes.”

Conclusion

During the course work on the topic “Development of a technological process for restoring a valve of the D-37 engine,” I analyzed the processes for restoring a part, the causes of a part failure and methods for eliminating the failure. A technological map was drawn up showing methods for restoring the part. When restoring the valve stem by spraying, I calculated the time standards; based on the time, it can be analyzed that it takes a lot of time to restore the valve stem, which can be reduced by changing the processing of the stem by grinding before spraying.

In carrying out this course work, we learned methods for assessing the quality of products, calculating and analyzing technological and dimensional chains, analyzing technological processes, choosing rational schemes for placing workpieces, calculating errors that determine the accuracy of machining, calculating allowances, optimal processing modes that ensure obtaining the specified quality parameters parts, and students must learn to calculate time standards and costs for obtaining parts.

We also received practical skills in designing technological processes and machining to obtain the specified parameters of a part.

Literature

1. P. F. Dunaev, O. P. Lilikov: Design of units and machine parts. Moscow "Higher School". 1998. - 441 p.

2. N.F. Baranov, E.A. Shishkanov: Guidelines for completing coursework in the discipline “Fundamentals of technology for production and repair of automobiles.” Kirov: Vyatka State Agricultural Academy, 2005. - 67 p.

3. Matveev V.A., Pustovalov I.I. Time standards for disassembly, assembly and repair at repair plants.

4. Shadrichev V.A. Fundamentals of automotive technology and car repair, -L: Mechanical Engineering, 1976. - 560 p.

5. Volovik V.L. Handbook on restoration of parts, - M: Kolos, 1981. - 381 p.

6. Processing of metals by cutting: Technologist's Handbook / A.A. Panov, V.V. Anikin, N.G. Beim, etc. Ed. A.A.Panova. M: Mechanical Engineering, 1988. - 736 p.

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Course work

on the topic: “Development of devices and technological

cards for part restoration"

EXPLANATORY NOTE

1. Selecting a part restoration method

3. Economic part

4. Calculation of fixtures

Literature

INTRODUCTION

The purpose of the course work is an in-depth study of repair technology and its organization at repair enterprises.

When performing work, it is necessary to master the methodology for developing technological processes for restoring parts.

1.Selecting a method for restoring a part

1. The choice of a rational method for restoring a part is influenced by the following factors:

1.1 Part material;

1.2 Amount of wear;

1.3 Nature of loading;

1.4 Lubrication conditions;

1.5 Cost of restoration.

2 There are also 3 main criteria for choosing a method for restoring a part:

2.1 Technological assessment of various recovery methods and technological capabilities.

2.2.Durability criterion

2.3.Technical and economic criterion linking the durability of a part with the economics of its restoration.

3 Route map for restoring the part.

Assessing these factors and criteria, we prescribe the following operations to restore the shaft:

05 Operation welding

10 Operation turning

15 Operation milling

20 Operation grinding.

Grinding the surface for bearing 2 with transverse feed until signs of wear are removed.

25 Operation galvanic.

Remaining the seats for the bearing.

1 Insulation of surfaces that cannot be restored with GF-30A paint

2 Hanging parts in a bath of electrolyte with a density of 70%

3 Anodic etching of the surface of parts in order to remove oxide films and impart a crystalline structure to the surface

4 Cold water rinsing

5 Rinse with hot water 60C

6 Neutralization of the surface of the part to prevent corrosion with trisodium phosphate

7 Rinse with hot water 70C.

30 Operation grinding with transverse feed

Transition 1 rough grinding of the surface for the bearing

Transition 2: fine grinding of the surface for the bearing

1.2 Rationale for the method of restoring a part

To restore the required layer of metal, we prescribe a galvanic operation - stagnation, since with this type of operation it is possible to build up the required layer of metal. It is more expedient to use this type for restoring a part, since when remaining, it is possible to achieve the desired layer of metal on the restored surface with the least loss compared to other types of surface restoration operations. The final operation to restore the nominal size is grinding. To restore the shaft splines, we weld it and mill it.

2. Development of a technological map for the restoration of a part

The technological map includes all the main technological recovery operations.

The initial data for developing a technological map are:

A sketch of the part indicating dimensions and defects, made taking into account the requirements of the ESKD;

Technical conditions and instructions for troubleshooting parts and connections when repairing a machine;

Albums of technological maps for the restoration of parts.

The shaft has the following defects:

Wear of bearing surfaces;

Wear shaft splines in width.

Part characteristics:

name roller;

Catalog No. 25.37.213;

material Steel 18ХГТ;

number of parts in the batch is 10;

hardness HRC 57-64

Weight 1.93 kg.

05Operation welding the shaft splines

For brewing we use manual electric arc welding, namely the TSP-2 welding transformer.

We determine the mass of deposited material when restoring a part:

Q = b h l ρ, (1)

Where b width of the weld seam, cm;

h the height of the weld seam along with the processing allowance,

Cm;

l weld length, cm;

ρ density of the deposited material, gr/

ρ = 7.8 g/

Q = 20 6.5 80 7.8 = 81 g.

Determine the strength of the welding current:

I = (20+6 d ) d , A (2)

Where d diameter of the welding electrode, mm;

We accept d = 4mm.

I = (20+6·4)·4 = 176 A.

We determine the standard time for performing a welding operation:

, (3)

Where - main time, min;

Auxiliary time, min; Tvs = 2 min.,

Preparatory and final time, min; Tp.z. = 1.8 min.

Additional time, min;

n - number of parts in the batch. n = 10 pcs.

Determining the main time

, (4)

Where Q mass of deposited material, g;

A coefficient taking into account the length of the seam

We accept A = 1, with L ‹ 200 mm.

m coefficient taking into account the position of the seam,

Position horizontal m = 1.

K = 1.25 coefficient.

I - welding current strength, A.

Additional time will be determined by the formula

(5)

The standard time for a welding operation was 28.3 minutes.

10 Operation turning of a welded spline shaft

Turning is carried out to return the correct geometric shape of the deposited surface.

Determine the cutting depth:

(6)

Where is the allowance for diameter, mm; We accept =3.2 mm.

Feed S (mm/rev.) selected according to the table from the reference literature

We take S = 0.8 mm/rev.

Determining the cutting speed

(7)

Where t cutting depth, mm;

S feed, mm/rev.;

T tool life, min. We take T = 90 min.

C and m coefficients. C = 41.7; m = 0.125.

X = 0.18, when processing steel

y = 0.27, when processing steel

Knowing the cutting speed and diameter of the workpiece, we determine the rotation speed

(8)

Where V cutting speed, m/min;

d workpiece diameter, mm.

By checking the obtained value with the machine’s passport data, we establish the actual spindle speed. Select a screw-cutting lathe 1K62 and

(9)

Calculation of the standard time for performing a turning operation:

(10)

Where Tsht piece time, min;

Тпз preparatory final time, min;

Тпз = 6.0 min.

(11)

Where Top operational time, min.

(12)

Tvs auxiliary time, min. We accept TVs = 0.44 min.

(13)

Where L length of the treated surface, mm; L =85mm

n rotation speed,

i number of tool passes.

T orm = 0.046 Top.

T op = 0.44 + 0.4 = 0.8 min,

T os = 0.025·0.8 = 0.02 min,

T orm = 0.046·0.8 = 0.03 min,

Tn = 0.8+0.02+0.03+ 6.0/10 = 1.45 min.

The standard time for performing a turning operation was 1.45 minutes.

15 Operation milling, cutting shaft splines

We choose a milling cutter with a cylindrical shank GOST 8237-57 made of high-speed steel. Diameter 20 mm, number of teeth Z = 5.

Determining the feed per tooth:

We accept S z = 0.2 mm/tooth.

We determine the feed per revolution of the cutter:

S o = S z z, (15)

S o = 0.2 5 = 1mm/rev.

Determine the cutting speed:

(16)

Where D outer diameter of the cutter, mm;

T cutter life, min. T = 120 min,

B milling width, mm.

Values, q, m, x, y, z, n should be selected from the table in the reference literature.

thirty; q = 0.45; m = 0.33; x = 0.3; y = 0.3; z = 0.1; n = 0.1.

Substituting these values into the formula, we have:

Determine the rotation speed of the cutter:

(17)

Where d cutter diameter, mm.

Choose a universal milling machine 6M82G and = 200

We calculate the actual cutting speed:

(18)

We calculate the time required for a milling operation:

(19)

Where T pcs piece time, min;

T pz preparatory final time, min;

T pz = 8.4 min.

(20)

Where is T op operational time, min;

(21)

Where That main time, min;

T sun auxiliary time, min. We accept

T sun = 0.44 min.

(22)

Where L cutting depth, mm;

L =5mm

n rotation speed,

S tool feed, mm/rev.

i number of tool passes.

Tos time for personal needs, min. Tos = 0.025 Top;

Brake time for servicing the workplace, min.

Torm = 0.04 Top,

Top = 4 + 0.44 = 4.44 min,

Tos = 0.025 4.44 = 0.11 min,

Brake = 0.04 4.44 = 0.18 min,

Tsht = 4+0.44+0.11+0.18=4.73min,

Tn = 4.73 + 8.4/10 = 5.57 min.

The standard time for performing a milling operation was 5.57 minutes.

20Operation Rough grinding of surface 1 for the ball bearing until wear marks are removed from a diameter of 34.97 mm to a diameter of 34.92 mm.

Cylindrical grinding machine 3A151;

Tool grinding wheel diameter PP600x30x305;

Installation of the part - into the cartridge;

Processing conditions with cooling;

Type of grinding round external with transverse feed.

Transition 1 - rough grinding of surface 3 under the collar from a diameter of 34.97 mm to a diameter of 34.92 mm

(23)

where V - rotation speed of the part,

V =20...80 rpm select V =30 rpm.

n d =300

(24)

Where is T pz

T pz = 16 min.

(25)

where T op operational time, min;

(26)

Where is T o main time, min;

T sun

We accept T sun = 0.43 min.

(27)

where n d

S pop

S pop =0.0025 mm/rev.

25 Operation - leaving the surface for the bearing.

Before you start remaining, you need to insulate those surfaces that will not need to be treated. Insulation serves to store geometric dimensions and prevent loss of electricity and metal. It is performed using permanent insulating materials (thin rubber, sheet celluloid, insulating tape, film polymer materials, cerazin, plastisol, etc.).

Taking into account the allowance for grinding, it is necessary to increase the metal to a diameter of 35.102 mm

Determining the thickness of the layer

The application of the metal layer must be smooth, dense, without gaps or cavities.

Coating

Equipment:

Bath 70-7880-1091.

Current converter AND500/250.

Electrolyte: ferrous chloride 500 g/l, hydrochloric acid 1.5 g/l.

Preparing the part for ironing:

Electrolytic activation and etching before ironing is carried out in a solution of sulfuric acid. Sulfuric acid electrolytes Remaining is obtained by directly dissolving ferrous sulfate (ferrous acid) in a working bath. After preparing for the resting, they begin the resting itself. Remaining is carried out in a metal bath lined with rubber.

Standard time T N determined by the expression

T H = (28)

where t 0 duration of electrolytic deposition of metals in the bath, h;

t 1 time for loading and unloading parts ( t 1 =0.1-0.2h);

To PZ coefficient taking into account additional and preparation

Conclusive tense (K PZ =1.1-1.2);

n D number of parts, n D = 10pcs;

ή AND bath utilization factor (ή I =0.8-0.95).

The exposure time of the part in the bath is determined by the formula

t0 = (29)

where h extension thickness, mm;

γ metal deposition density, g/cm 3, γ=7.8 g/cm3;

C electrochemical equivalent, g/Ah, C=1.042 g/Ah;

ή B metal current output, ή B = 80-95%.

t 0 =

T N =

The standard time for ironing surfaces was 3.9 minutes.

30 Operation grinding.

Transition 1 - rough grinding of surface 1 for the bearing from a diameter of 35.102 mm to a diameter of 35.052 mm

The processing allowance is determined by the formula

Determine the rotation speed of the part

(30)

where V - rotation speed of the part,

V =20...80 rpm select V =30 rpm.

We perform turning on a machine model 3A151 n d =300

Calculation of time standards for rough grinding

(31)

Where is T pz preparatory final time, min,

T pz = 16 min.

(32)

where T op operational time, min;

K extra time coefficient K=7.

(33)

Where is T o main time, min;

T sun auxiliary time, min.

We accept T sun = 0.43 min.

(34)

where n d rotation speed of the part, ;

S pop transverse feed per revolution of the part,

S pop =0.0025 mm/rev.

The standard time for rough grinding of the surface under the collar was 2.12 minutes.

Transition 2 - fine grinding of surface 1 for the bearing from a diameter of 35.052 mm to a diameter of 35.002 mm

Determine the rotation speed of the part

(35)

where V - rotation speed of the part during finishing grinding,

V =2…5 m/min select V =5 m/min

We perform turning on a machine model 3A151 n d =60.

Determining the standard time

(38)

where Тпз preparatory final time, min;

Tpz = 16 min.

(36)

Where is T op operational time, min;

K extra time coefficient, K=7.

(40)

Where is T o main time, min;

T sun auxiliary time, min.

We accept TVs = 0.43 min.

(37)

Where n d rotation speed of the part:

S pop transverse feed per revolution of the part,

S pop =0.0015 mm/rev.

The standard time for final grinding of the surface under the collar was 2.36 minutes.

3. Economic part

In general, the cost of restoring a part at an auto repair plant is determined by the formula

St = ZP + Sm + Siz + OPU, (38)

where salary wages of production workers with

Accruals, rub;

See cost of repair materials, rub;

Ciz cost of a worn part, rub;

OPU expenses associated with organizing production and

Management, rub.

Wages are determined taking into account the entire complex of operations provided for by the technological process of restoring a specific part, according to the formula:

(39)

where are the time standards for performing operations

Technological recovery process in calculation

For one part, min;

Hourly ratescorresponding categories

To perform operations, rub;

Kp coefficient taking into account the premium surcharge,

We accept Kp = 1.25;

Kd coefficient taking into account additional

Salary, Kd = 1.3;

Ks coefficient taking into account contributions to social insurance funds, Ks = 1.385.

The cost of repair materials is determined as the sum of costs for all types of materials used to restore the part.

(40)

where is the rate of material consumption, kg/child;

Price 1 kg of material, rub/kg.

The rate of material consumption can be approximately determined by the formula

(41)

where S area of the growing surface, ;

h coating thickness taking into account processing allowance, mm;

γ material density, ;

K - coefficient taking into account inevitable losses

Material, K = 1.25.

Cost of consumables for electroplating

Cost of electrodes

The cost of a worn part is determined by the price of scrap metal:

(42)

where is the price of scrap, rub/kg;

M mass of worn part, kg.

Expenses associated with the organization of production and management can be taken in the amount of 200...300% of wages

OPU = 2.5·41.3= 103.25 rub.

St = 41.3+ 12.92+ 0.2 + 5.67+ 103.25= 163.34 rub.

Conclusion: the cost of restoration at a car repair company is 163.34 rubles.

4. Calculation of fixtures

To press out the bearing ring, a force of 300 kN is created due to the load screw and the load nut, based on this, the normal tensile force of the bolt

(64)

where F - force acting on the bolt, N;

d - minimum thread diameter, mm;

The normal tensile stress of the bolt should not exceed the permissible [ G p ]= 580 MPa.

G p =14.9 MPa< [ G p ]= 580 MPa, the strength condition is met.

Checking the threaded connection for thread collapse.

Calculation of thread pressure

(65)

where F - calculated axial force acting on the bolt, N;

d 2 - average thread diameter, mm;

h - working height of the bolt, mm;

P - thread pitch;

z = H/P - number of turns at thread depth in the body

z= 20/1.5=13.3

h =20mm

Р=4.85<[Р]=6МПа условие прочности на смятие резьбы выполнено.

The condition is met.

Literature

I.S.Sery and others. Coursework and diploma design on reliability and repair of machines. M.: Agropromizdat 1991.
1. Sherstobitov V.D. Guidelines for course work.
2. Volovik I.A. Handbook for restoring parts: M, -1975
3. N.F. Baranov, R.F. Kurbanov, V.A. Likhanov, A.A. Loparev. Graduate design. Kirov 2005
4. Novikov M.P., Orlov P.N. Metalhead's Handbook. Volume 4 M.: Mechanical Engineering, 1977. 720 p.

6. Directory “Metal cutting modes” edited by Yu.V. Baranovsky Mechanical Engineering, M. 1972.

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Repair of the main parts of the unit being repaired is carried out using route technology.

The main parts of the repaired unit include shafts, axles, gears and gears. The shafts have smooth cylindrical surfaces, necks, splines, collars, grooves and threaded holes. During operation, wear of the support and landing journals and collars, and wear of the splines may appear on these surfaces.

Repair of bearing seats. No significant damage to rubbing surfaces in the form of wear. They are eliminated by finishing with special pastes or grinding; in case of large wear, as well as in the event of the appearance of conicity and ovality, restoration of the seats is carried out by processing to repair size and surfacing, metallization or galvanic method, in case of wear of more than two mm. The restoration of the shafts is carried out by surfacing, extension of the necks by chrome plating. After building up the metal, the seats are ground.

Repair of gears and gears. They are made of alloy steels; during operation, gears and gears develop the following defects: wear and breakage of teeth, wear of the keyway along the width are eliminated by automatic arc welding and surfacing or manual arc welding and surfacing. This method is characterized by simplicity, economic feasibility and low labor intensity. When the teeth are worn, they are restored by industrial surfacing with an oxygen acetylene flame or electric arc surfacing. Electric arc surfacing is carried out using electrodes with high-quality coatings; when gas surfacing, rods of the same chemical composition as the metal of the gear wheel are used. Worn gears of small modules up to 5-6 mm are restored by continuous surfacing, followed by milling or planing; replacement of broken teeth with new ones is possible only in low-speed gears, repair method depends on the strength of the gear rim and material

Route map

The route kata is in the appendix

Development of a technological process for repairing the driven shaft using route technology

005 locksmith

010 screw-cutting turning

015 locksmith

020 surfacing

025 thermal

030 screw-cutting turning

035 milling

040 thermal

045 grinding

050 final control

Technological map for part repair

The technological map for repairing the part is in Appendix B.

Surfacing operational map

The welding operation chart is in Appendix B.

The technological process includes

- sequence of production operations (route) to eliminate defects;
- determination of dimensions, tolerances, surface cleanliness of the part being repaired;
- selection of the type of equipment, equipment, tools;
- calculation of time standards for processing and qualification of work.

Due to the fact that restoration (manufacturing) work is carried out on different equipment, an important element of the process is the selection of the part base, against which all other parameters are calculated.

Operation - this part of the process in one area; a transition is an element of an operation during processing; an important part of the technological process is the scale of repair; identical positions in it; repair ratio; stock standards of the same name and the required range of parts in the warehouse called batch size.

Transmission units include: clutch, gearbox, transfer case, front, middle and rear axles, cardan transmission.

After washing, the disassembled units are finally disassembled into parts. The parts are washed in a secondary washing machine, defective, sorted into groups, assembled according to standard sizes, weight, and balanced. The most worn parts are sent to TsVID - workshops for restoring worn parts.

Technological methods used in the restoration of parts include: fusion welding, electric arc, electroslag under a layer of flux, in an environment of protective gases and water vapor, vibration arc, argon arc, gas, plasma, foundry, beam (electronic, laser) high frequency, electric contact, friction, explosion , mining, pressing, diffusion, ultrasonic, induction, cold, condenser, gas press, forging, spraying (plasma, gas flame); metallization (gas, electric arc, high-frequency plasma); soldering (soft, hard), electrolytic metal coatings (chrome plating, iron plating, nickel plating, galvanizing); use of polymer materials (with application in a fluidized bed using a gas-flame method, pressing, gluing); pressure treatment (expansion, upsetting, rolling, rolling, drawing, upsetting, electromechanical processing); metalworking and mechanical processing (sawing, scraping, grinding, reaming, grinding, pinning, threading, installing tightening and other elements, attachments and acceptable repair parts); electrical processing methods (anodic-mechanical, electrochemical, electrocontact, electric pulse, electroerosive); hardening treatment (thermal, thermomechanical, chemical-thermal, surface-plastic, diamond tool processing, superfinishing).

A variety of different restoration methods allows you to create a certain reserve of parts for operating machines, significantly reduce their downtime, and increase the availability factor.

Threaded connections are restored by surfacing and cutting new threads; driven with a calibrated die; body parts undergo several restoration methods. The shafts are straightened, machined to the next repair size or bushed.

Riveted joints are replaced from repair stock; stick on, rivet new ones;

Bearings are either changed or the races are restored by remaining, galvanic methods

Worn splines are restored by surfacing under a layer of flux or in a carbon dioxide environment, followed by milling and grinding to the size according to the working drawing. The depressions between the splines and the spline neck are fixed with longitudinal seams. The end of the electrode wire is installed in the middle of the depressions between the slots. In order to mechanize repair work, parts during restoration are divided into groups (classes) according to their affiliation: body parts, made of various alloys, including cast iron (MF, KCh, MCh), low-alloy; special alloys AL-4; MD 4 non-ferrous metals: shafts - smooth, stepped, camshafts, crankshafts made of low-alloy alloys 12 KhGT, 18 KhGT, ST 45;50; 60; springs; gears - with internal and external teeth. Recovery methods use operations:

- thermal for annealing hard hardened surfaces (gear teeth, shafts, splines, cardan parts, splined hubs, as well as normalization, tempering, carburization, etc.).
- metalworking, for straightening shafts, drilling holes, riveting blocks, linings, reaming, countersinking, countersinking:
- lathe - screw-cutting, for removing, facing, cutting threads, additional parts, mandrels
- surfacing (electroplating) spraying - for restoration to nominal values;
- screw-cutting lathe, for grooving, removing excess layer after surfacing, galvanizing and for transfer to other departments;
- tooth-resing (gear-cutting, slotting) - for keyways, cutting teeth, splines;
- thermally - hardening - to bring its strength to the specifications and technical specifications of the manufacturer
- flat-cylindrical grinding to obtain a certain surface cleanliness (see manual and tolerance fields, classification of cleanliness);
- final control for acceptance of parts by size, accuracy level, surface cleanliness, tolerances and fits, hardness and deviations from the nominal value.

The list of typical restoration operations has codes from 005 to 050 through 5 units and is determined for each part individually.

The technological process of restoring parts can be presented in the form of a route, route-operational, and operational description. In the route and route-operational description of a technological process, the route map is one of the main documents on which the entire process is described in the technological sequence of operations.

According to the drawn up control, sorting and fault detection cards, we draw up MK route maps for exactly:

MK on the cardan shaft (hardness of the journal for the bearing HRC 60-65)

005 - thermal (annealing of the shafts of a resistance heating furnace in a protective environment);
010 - turning - screw-cutting (will remove worn surfaces along the diameter for surfacing, grinding, milling splines);
015- surfacing (metallization on special equipment with a metal shutter;
020- turning - screw-cutting (groove to nominal size with allowance for grinding)
025- thermal;
030- centerless grinding
040- final control

Technological documentation for the restoration of a part includes:

· repair drawing of the part (RF);

· part restoration route map (MK);

· operational cards for part restoration (OK);

· sketch cards (SC) for operational cards.

Repair drawings are carried out in accordance with the requirements of ESKD standards, taking into account the rules provided for by GOST 2.604 “Repair drawings”.

Initial data for developing a repair drawing:

· working drawing of the part;

· technical requirements for a new part;

· technical requirements for defective parts;

· technical requirements for the restored part.

The basic requirements when performing repair drawings are as follows:

areas to be restored are highlighted with a solid main line of thickness, the rest of the image is marked with a solid thin line of thickness . The designation of a repair drawing is obtained by adding the letter P (repair) to the part designation;

on the drawings of parts restored by welding, surfacing, metal coating, threaded inserts, etc., it is recommended to make a sketch of the preparation of the corresponding section of the part for restoration;

when using surfacing, soldering, etc., the repair drawing indicates the name, brand of the material used in restoration, as well as the standard number for this material.

Repair drawing included.

1. The actual drawing of the part, indicating defects and dimensional and accuracy parameters of the surfaces being restored.

2. Names of defects and their repetition rates.

3. Technical requirements for the restoration of the part.

4. Schemes for basing a part during restoration and machining.

5. Basic and additional methods for eliminating defects.

6. Technological route for restoration. It is indicated on the route map.

1. Names of all operations according to the order of their execution (cleaning, troubleshooting, surfacing, etc.); operations are numbered in numbers divisible by 5 (005, 010, 015, etc.);

2. Equipment to perform each operation.

3. Name and characteristics of the material used to perform each operation.

4. Piece time to complete each operation.

Operational cards are intended to describe technological operations indicating transitions, processing modes, data on technological equipment, unit time standards for performing operations and transitions.

In operational cards, after the name of the operation (transition), technical requirements related to the operation (transition) being performed are indicated. Transition numbers in operational maps are indicated in Arabic numerals in technological sequence. Record transitions.

Sketch cards are performed for each operation. They reflect the following information: a sketch of the part, a location diagram when performing this operation, surface dimensions or other characteristics obtained when performing this operation.

Related information:

Behavioral - social goals. Since the main problem in a schizoid case concerns the issue of attachment, the therapist's goal will be to restore it