1CylinderblockmachiningprocessdesignEnginepartsengineblockisamorecomplexstructureofsparepartsbox,itshighprecision,complexprocess,andtheprocessingqualitywillaffecttheoverallperformanceengine,soithasbecometheenginemanufacturersfocuspartsone.TechnicalCharacteristicsoftheenginecylinderblockCylindercastforawholestructure,anditsupperpart4cylindermountinghole；cylinderstandardcylinderisdividedintoupperandlowerdivisionsintotwoparts；cylindertotherearofthefront-sidearrangementofthepreviousthreecoaxialmountingholeofthecamshaftandtheidleraxlehole.Cylinderprocessfeaturesare:thestructureofcomplexshape；processingplane,morethanholes；unevenwallthicknessandstiffnessislow；processingofhighprecisiontypicalofbox-typeprocessingpart.Themainprocessingofthesurfaceofcylinderblocktopsurface,themainbearingside,cylinderbore,themainandcamshaftbearingboreholesandsoon,theywilldirectlyaffectthemachiningaccuracyoftheengineassemblyprecisionandperformance,mainlyrelyonprecisionequipment,industrialfixturesreliabilityandprocessingtechnologytoensurethereasonableness.1.EngineblockprocessdesignprinciplesandthebasisforDesignTechnologyprogramshouldbetoensureproductqualityatthesametime,givefullconsiderationtotheproductioncycle,costandenvironmentalprotection；basedontheenterprisesabilitytoactivelyadoptadvancedprocesstechnologyandequipment,andconstantlyenhancetheirleveloftechnology.Engineblockmachiningprocessdesignshouldfollowthefollowingbasicprinciples:(1)Theselectionofprocessingequipment,theprincipleofselectionadoptedtheprincipleofselectionadoptedtheprincipleofcombiningrigid-flexible,processingeachhorizontalmachiningcenterislocatedmainlysmalloperationswithverticalmachiningcenter,thekeyprocessacrankhole,cylinderhole,balancershaftholeHigh-speedprocessingofhigh-precisionhorizontalmachiningcenter,anupperandlowernon-criticalprocessesbeforeandafterthefour-dimensionalhigh-efficiencyroughmillingandhaveacertainadjustmentrangeofspecialmachineprocessing；(2)focusonakeyprocessinprincipleprocessthebodycylinderbore,crankshafthole,BalanceShaftholesurfacefinishingandthecombinationofprecisionmillingcylinderhead,usingaprocessfocusedonasetupprogramtocompleteallprocessingelementsinordertoensureproductaccuracyThekeyqualityprocessestomeetthecylindercapacityandtherelevant2technicalrequirements；Accordingtothetechnologicalcharacteristicsofautomobileenginecylinderblockandtheproductionmandate,theengineblockmachiningautomaticproductionlineiscomposedofhorizontalmachiningcenterCWK500andCWK500Dmachiningcenters,specialmilling/boringmachine,verticalmachiningcentersmatec-30Landotherappliances.(1)topandbottom,andtilecoveredonlythecombinationofapertureroughmillingmachinededicatedtothismachinetodouble-sidedhorizontalmillingmachine,usingmovingtabledrivenparts,machinetoolsimportedSiemensS7-200PLCsystemcontrol,machinecontrolcabinetsetupanindependent,cuttingautomatetheprocessiscompletedandtwokindsofautomaticandadjustthestate；(2)high-speedhorizontalmachiningcentermachiningcentercanberealizedCWK500themaximumflowofwetprocessing,butbecauseofequipment,automaticBTAtreatmentsystemthroughthebuilt-intrayunderthewide-typechipconveyorandthecompletionofthemachiningcentercanbedryprocessing；machinetoolspindlespeed6000r/min,rapidfeedingspeed38m/min；(3)Thecombinationoffrontandrearfaceroughmillingmachinetoolusinghydraulictransmission；controlsystemimportedSiemensS7-200PLCsystemcontrol,machinetoolshaveacertainflexibility；(4)ThespecialmachineTXK1500thismachineverticalmachiningcenterbythemodificationofshape,withverticalmachiningcenterfeaturesandperformance,thismachinehashighstrength,highwear-resistant,highstability,highaccuracy,high-profileetc.；(5)high-speedverticalmachiningcentermatec-30Lofthemachiningcenterspindlehighspeed9000r/min.ControlsystemusesSiemensSINUMERIK840Dcontrolsystem；(6)high-speedhorizontalmachiningcenterspindleCWK500Dhighestspeed15000r/min.2.EngineblockmachiningprocessdesignthemaincontentEngineblockcomplexstructure,highprecision,argesize,isthin-walledparts,thereareanumberofhighprecisionplaneandholes.Engineblockmachiningprocesscharacteristics；mainlyflatandtheholeprocessing,processingofflatgenerallyuseplaning,millingmethodssuchasprocessing,processingofholeusedmainlyboring,processingandmulti-purposedrillingholes.Asthecylindercomplexstructure.sohowtoensurethatthemutualpositionofthesurfaceprocessingprecisionisanimportantissue.3.1TheselectionofblankEngineblockonthematerialsusedaregenerallygraycastironHT150,HT200,HT250,thereisalsocastaluminumorsteelplate,thisengineblockusinghigh-strengthalloycastiron.Cylinderintheprocessingpriortoagingtreatmentinordertoeliminatestressandimprovetheroughcastingmechanicalproperties.Improvetheroughaccuracy,reductionofmachiningallowance,istoimprovetheautomatedproductionlinesystemproductivityandprocessingqualityoftheimportantmeasures.Asthe3foreignbox-typepartsofroughqualityandhighprecision,anditsproduction-linesystemhasbeenimplementeddirectlyontheblankline,notonlyeliminatingtheneedforblankcheckdevicealsosavestheroughqualityproblemsduetowasteofmachiningtime,increaseoverallefficiency.Therefore,therefinementofroughistoimprovetheproductivityofthemostpromisingwayout.Fortheengineblockproductionline,canberoughinpartson-linepre-millingsixface,removingmostofthemargin,tofacilitatedirecton-lineparts.3.2MachiningprocessselectionandprocessingofthebenchmarkChoosetherightprocessingtechnologybaseisdirectlyrelatedtotheprocessingqualitycanensuretheparts.Generallyspeaking,processbenchmarkingcanbedividedintocoarseandfinereferencebase.(1)Thebaselinefortheon-linethickrough,whichisparticularlyimportantthechoiceofbenchmarkcrude,ifcrudebenchmarkchoiceunreasonable,willtheunevendistributionofmachiningallowance,processingandsurfaceoffsets,resultinginwaste.Inthecylinderproductionline,wehaveadoptedforthecoarsesideofthebase；(2)Refinedthebaseofthisboxfortheengineblockparts,thegeneraluseofsidetwosalesforafullrangeofuniformbenchmarks,Forthelongerautomatedproductionpositioning,therefore,willbedividedinto2-3segmentpinholesused.Inthecylinderpinholeoftheprocess,wehaveadoptedtotheside,bottomandthespindleholepositioning,intheprocessingcenterontheprocess.3.3MachiningProcessingStagesandprocessesofthearrangementsOftenapartofmanyapparentneedforprocessing,ofcourse,thesurfacemachiningaccuracyaredifferent.Processingofhighprecisionsurface,oftenafterrepeatedprocessing；Asfortheprocessingofthesurfaceoflowprecision,onlyneedtogothroughoneortwoonthelist.Thus,whenthedevelopmentprocessinordertoseizetheprocessinghighprecisionsurface,thisconflict,thereasonablearrangementprocessesandrationaldivisionstageofprocessing.Arrangetheorderoftheprincipleofprocessis:afterthefirstcoarserefined,thefirstsurfaceafterthehole,thefirstbenchmarkother.Intheengineblockmachining,thesameshouldfollowthisprinciple.(1)roughingstageengineblockmachiningprocess,thearrangementsforroughingprocess,tofullycarryoutroughrough,trimmostofthemargininordertoensureproductionefficiency；(2)semi-finishingphaseoftheengineblockmachining,inordertoensuretheaccuracyofthemiddleofsomeimportantsurfaceprocessing,andarrangesomesemi-finishingoperations,willberequiredaccuracyandsurfaceroughnessofthesurfaceofthemiddleofsomeprocessingtocomplete,whiledemandingthesurfaceofsemi-finished,toprepareforfuturefinishing；(3)Thefinishingstageofrequiringhighaccuracyandsurfaceroughnessofthesurfaceprocessing；(4)secondaryprocessing,suchassmallsurfacescrewholes,youcanfinishofthemajorsurfaceaftertheonehand,whentheworkpiecedeformationprocesslittleimpactatthesame4timealsoreducedtherejectionrate；Inaddition,ifthemainsurfaceofawaste,thesesmallthesurfacewillnothavetobeprocessed,thusavoidingawasteofman-hours.However,iftheprocessingisveryeasyforasmallsurfacebumpsthemainsurface,itshouldbeplacedonasmallsurfacefinishpriortothemainsurfacefinishing；(5)shouldmakeproperarrangementsforsecondaryprocessessuchasproductinspectionprocess,inpartroughingstage,thekeyprocessbeforeandafterprocessing,sparepartsalltheprocessinghasbeencompleted,shouldbeappropriatearrangements.Stageofprocessingdivision,hasthefollowingadvantages:First,itcantakemeasurestoeliminatetheroughworkpieceafterthestress,toensureaccuracy；second,finishingontheback,andwillnotdamageduringtransportthesurfaceoftheworkpiecehasbeenprocessed；again,firstroughingthesurfacedefectscanbedetectedearlyandpromptlydealwithrough,donotwasteworkinghours.Butmostsmallparts,donotsubverythin.3.4cylindersurfaceofthemainprocessingandsecondaryprocessesCylindersurfaceandsupportthemainprocessingoperationsare:(1)planeprocessingatpresent,themillingofengineblocksistheprimarymeansofplanarprocessing,domesticmillingfeedrateisgenerally300-400mm/min,andforeign2000-4000mm/minmillingfeedratecomparedtofarcry,tobeonincreasing,therefore,improvethemillingfeedrate,reduceoverheadtimeistoimprovetheproductivityofthemajormeansoffinishinganumberofplaneengineblockwhenthemillingfeedratetoreach2399mm/min,greatlyimprovedefficiency；Topsurfaceofthecylindermillingisakeyprocessintheprocess,theflatnessrequirementsfor0.02/145mm,thesurfaceroughnessofRa1.6um.Processinginthecylinder,theuseofsideandspindlebearingborepositioning,top,bottomandmiddlevagayonlyaperturewhileprocessingusedintheprocessinglineoutsideofthekni