中速柴油机机体多路孔高精度控制与分析

High-precision Control and Analysis of Multi-Bores in Medium Speed Diesel Engine Block

  • 摘要: 针对中速柴油机机体多路孔位置度、同柱度、平行度、垂直度、表面粗糙度尺寸公差要求高的问题,结合制造过程中的人、机、料、法、环五要素进行分析,确定主轴承孔是加工缸套孔、两路凸轮轴孔、过桥齿轮孔一和过桥齿轮孔二最为重要的整个机体的第一基准。由于机体结构以及附件头尺寸限制,只能采用二次装夹完成。在旋转工作台需重新建立坐标系时,采用宏程序一次定位,在机体四周建立四个加工坐标系,从而提高定位精度。加工过程中,对喷油凸轮轴孔和进排气凸轮轴孔的粗、半精及精加工节拍,以及一号、二号附件头每30 min的伸长量进行实测,并利用五阶多项式最小二乘法拟合其随时间的变化规律,进而实现动态补偿。最终,以编号1和编号8轴承孔为测量基准,实测多路孔偏差均满足技术要求,从而实现了中速柴油机机体多路孔的高精度控制。

     

    Abstract: In response to the stringent dimensional tolerance requirements of medium speed diesel engine blocks, such as positional accuracy, coaxiality, parallelism, perpendicularity, and surface roughness of multiple holes, an analysis was conducted based on the five key factors of the manufacturing process: personnel, machines, materials, methods, and environment. The main bearing bore was identified as the primary datum for the entire block, as it governs the machining of the cylinder liner bore, dual camshaft bores, and two bridge gear bores. Due to structural constraints and the size of accessory heads, secondary clamping was required. When re-establishing the coordinate system on the rotary worktable, a macro program was used to achieve one-time positioning, setting up four machining coordinate systems around the block to improve positioning accuracy. During machining, the roughing, semi-finishing, and finishing cycles of the fuel injection and intake/exhaust camshaft bores were monitored, as well as the elongation of accessory heads No.1 and No.2 every 30 minutes. A fifth-order polynomial least squares fitting method was applied to model their variation over time, enabling dynamic compensation. Finally, with bearing bores No.1 and No.8 used as measurement references, the measured deviations of multiple holes all met technical specifications, thereby achieving high-precision control of multi-bore machining in the medium speed diesel engine block.

     

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