1英文原文EnginecylinderblockEnginecylinderblockisamorecomplexstructureoftheboxpartsintheengineparts,itshighprecision,processing,complexprocess,andtheprocessingqualitywillstillaffecttheoverallperformanceengine,soithasbecomeoneoftheenginemanufacturersfocusparts.Enginecylinderblockisthebasicenginepartsandskeletonandthegeneralassemblyofthebasecomponents.Cylindersroleissupportingandensuringthepiston,connectingrod,crankshaftandothermovingpartswork,theexactlocation；toensuretheengineventilation,coolingandlubrication；toprovideavarietyofauxiliarysystems,componentsandengineinstallation.1TechnicalCharacteristicsCylinderblockcastforawholestructure,anditsupperpart4cylindermountinghole；cylinderblockstandardcylinderblockisdividedintoupperandlowerdivisionsintotwoparts；cylinderblocktotherearofthefront-sidearrangementofthepreviousthreecoaxialmountingholeofthecamshaftandtheidleraxlehole.Cylinderblockprocessfeaturesare:thestructureofcomplexshape；processingplane,morethanholes；unevenwallthicknessandstiffnessislow；processingofhighprecisiontypicalofbox-typeprocessingpart.Themainprocessingofthesurfaceofcylinderblocktopsurface,themainbearingside,cylinderbore,themainandcamshaftbearingboreholesandsoon,theywilldirectlyaffectthemachiningaccuracyoftheengineassemblyprecisionandperformance,mainlyrelyonprecisionequipment,industrialfixturesreliabilityandprocessingtechnologytoensurethereasonableness.2ThecylinderprocessdesignprinciplesandthebasisforengineTechnologyprogramisthepreparationofthemasterprocessistoprocessplanningandkeyprocessequipmentdesignguidancedocuments.Thecorrectprocessofprogramdesign,facilitatethesystematicapplicationofnewscientificandtechnologicalachievementsandadvancedproductionexperience,toensureproductquality,improveworkingconditions,andimproveprocesstechnologyandprocessmanagementlevel.2.1ProcessdesignprinciplesDesignTechnologyprogramshouldbetoensureproductqualityatthesametime,givefullconsiderationtotheproductioncycle,costandenvironmentalprotection；basedontheenterprisesabilitytoactivelyadoptadvancedprocesstechnologyandequipment,andconstantlyenhancetheirleveloftechnology.Enginecylinderblockmachiningprocessdesignshouldfollowthefollowingbasicprinciples.(1)Theselectionofprocessingequipment,processingequipment,theprincipleofselectionadoptedtheprincipleofcombiningrigid-flexible,processingeachhorizontalmachiningcenterislocatedmainlysmalloperationswithverticalmachiningcenter,thekeyprocessacrankhole,cylinderhole,balancershaftholeHigh-speedprocessingofhigh-precisionhorizontalmachiningcenter,anupperandlowernon-criticalprocessesbeforeandafterthefour-dimensionalhigh-efficiencyroughmillingandhaveacertainadjustmentrangeofspecialmachineprocessing；(2)focusonakeyprocessinprincipleprocessthebodycylinderbore,crankshafthole,BalanceShaftholesurfacefinishingandthecombinationofprecisionmillingcylinderhead,usingaprocessfocusedonasetup2programtocompleteallprocessingelementsinordertoensureproductaccuracyThekeyqualityprocessestomeetthecylindercapacityandtherelevanttechnicalrequirements；(3)Allfixturesareusedhydraulicclamp,clampingcomponents,hydraulicpumpsandhydrauliccontrolcomponentsusedinGermanyortheUnitedStatesproducinghighqualityandreliablecomponents；(4)Thewholelineusedinallwetprocessing,usingstandaloneBTA,high-precisionmachiningprocessescriticalhorizontalmachiningcenterwithconstantcoolingandtoinstallhigh-precisionhigh-voltagedouble-circuitband-passfinefiltrationsystem,allwithhigh-pressureprocessingcenterinthecold.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.2.2ProcessdesignbasisAffecttheengineblockpartoftheprocessdesignfactorsaremanifold.Specifically,canbeunderstoodfromthefollowingaspects.(1)productobject,productdrawingsandtechnicaldocumentsrelatedtothecomplexityoftheengineblockundertheprecisionrequirementsoftheprocesstotakecorrespondingmeasures.Productiontargetsforthefour-cylinderautomobileenginecylinderblock；(2)theproductionprogram,theproductionofthenatureandtypeofproductionoftheengineblocktheproductionprogramof400million；(3)Theannualeffectivesystemofworkequipment,workingfor320days,withanaverageequipmentloadingrateof80%,twoshifts,16hours/day.3Themaincontentofenginecylinderblockmachiningprocessdesign3Enginecylinderblockmachiningprocesscharacteristics:mainlyflatandtheholeprocessing,processingofflatgenerallyuseplaning,millingmethodssuchasprocessing,processingofholeusedmainlyboring,processingandmulti-purposedrillingholes.Asthecylindercomplexstructure,sohowtoensurethatthemutualpositionofthesurfaceprocessingprecisionisanimportantissue.3.1TheselectionofblankEngineblockonthematerialsusedaregenerallygraycastironHT150,HT200,HT250,thereisalsocastaluminumorsteelplate,thisengineblockusinghigh-strengthalloycastiron.Cylinderintheprocessingpriortoagingtreatmentinordertoeliminatestressandimprovetheroughcastingmechanicalproperties.Improvetheroughaccuracy,reductionofmachiningallowance,istoimprovetheautomatedproductionlinesystemproductivityandprocessingqualityoftheimportantmeasures.Astheforeignbox-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,thegeneraluseof“sidetwosales”forafullrangeofuniformbenchmarks.Forthelongerautomatedproductionlinesystem,duetopinholesinthecourseofthewearandtearcausedbyinaccuratepositioning,therefore,willbedividedinto2-3segmentpinholesused.Inthecylinderpinholeoftheprocess,wehaveadoptedtotheside,bottomandthespindleholepositioning,intheprocessingcenterontheprocess.3.3MachiningProcessingStagesandprocessesofthearrangementsOftenapartofmanyapparentneedforprocessing,ofcourse,thesurfacemachiningaccuracyaredifferent.Processingofhighprecisionsurface,oftenafterrepeatedprocessing；Asfortheprocessingofthesurfaceoflowprecision,onlyneedtogothroughoneortwoonthelist.Thus,whenthedevelopmentprocessinordertoseizethe“processinghighprecisionsurface,”thisconflict,thereasonablearrangementprocessesandrationaldivisionstageofprocessing.Arrangetheorderoftheprincipleofprocessis:afterthefirstcoarserefined,thefirstsurfaceafterthehole,thefirstbenchmarkother.Intheengineblockmachining,thesameshouldfollowthisprinciple.(1)roughingstageengineblockmachiningprocess,thearrangementsforroughingprocess,tofullycarryoutroughrough,trimmostofthemargininordertoensureproductionefficiency；4(2)semi-finishingphaseoftheengineblockmachining,inordertoensuretheaccuracyofsomeimportantsurfaceprocessing,andarrangesomesemi-finishingoperations,willberequiredaccuracyandsurfaceroughnessofthesurfaceofthemiddleofsomeprocessingtocomplete,whiledemandingthesurfaceofsemi-finished,toprepareforfuturefinishing；(3)Thefinishingstageofrequiringhighaccuracyandsurfaceroughnessofthesurfaceprocessing；(4)secondaryprocessing,suchassmallsurfacescrewholes,youcanfinishofthemajorsurfaceaftertheonehand,whentheworkpiecedeformationprocesslittleimpactatthesametimealsoreducedtherejectionrate；Inaddition,ifthemainsurfaceofawaste,thesesmallthesurfacewillnothavetobeprocessed,thusavoidingawasteofman-hours.However,iftheprocessingisveryeasyforasmallsurfacebumpsthemainsurface,itshouldbeplacedonasmallsurfacefinishpriortothemainsurfacefinishing；(5)shouldmakeproperarrangementsforsecondaryprocessessuchasproductinspectionprocess,inpartroughingstage,thekeyprocessbeforeiningProcessingStagesandprocessTandafterprocessing,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/minmillingfeed