Improvement And Application Of Honing Machine For Engine Cylinder Block

Single feed honing is also general honing process, the formation of the mesh structure does not have a flateau,the support rate of surface is low, dimension precision is also low, it needs to run a certain period of time to stabilize the use of the running, it also causes high oil and fuel consumption, low power torque. Flat roofed mesh honing forms the the small groove on the cylinder surface through honing cylinder, the groove is regularly formed with mesh, it grinds the peak by specialized honing process, and forms small flateau. Its advantages are as follows:1. Oil saving function and good lubrication. If it does not have continuous, effective and adequate oil film between the piston and cylinder hole, it will form a dry grinding and have a greater wear and tear, ultimately affect the life of the engine. It saves oil in low areas for flat roofed mesh, full lubricates friction between the ring and the wall, it is a good solution to this problem.2. Reducing oil consumption. In the machining of flat roofed honing, peak, burr are removed, peak and burr formed as a result of general honing are removed by the cost of wear and tear piston ring and wall, and much iron chip falls into the oil pan, it need change oil frequently during engine running. It can be kept oil cleaner for flat roofed mesh technology, and reduces the chance of oil entering the combustion chamber, extends the replacement cycle oil, so as to reduces oil consumption.3. Good at piston ring sealing. Scientific measurements and calculations show that: the bearing friction area formed of general honing is less than the total area of 5%. During the flat roofed Honing, this ratio is over 80%. With the increase in contact area, it is obviously improved for sealing piston rings.Flat roofed mesh technology greatly improves the life of the engine, effectively reduces the use of oil and the harmful emissions, it's more environmentally friendly, it is also an important process in a modern engine plant.According to the original honing machine in this thesis, it made the original single-feed honing, two honing (rough honing, finish honing) into three honing (rough honing, finish honing,plateau honing), increased the active measuring device. According to the results of testing it can be carried out on the automatic compensation finish honing.Two kinds of process test about the cylinder bore precision on the same cylinder block are made,the honing stone material and honing stone fixation methods are respectively changed. By comparing the results,analysis shows that the existing product requirements are met,but the super-hard honing stone and adhesive fixation methods can significantly improve product quality.1. Super hard honing stone can obtain a better precision, it's cycle time and process is stability, and cost is not high.2. Adhesive honing stone methods may further improve the product quality,and to maintain process stability,although the replacement time is longer,but it can be resoled by more preparation of honing head.According the test results, it can be concluded that the superhard honing of adhesive fixation methods can significantly improve cylindricity and roughness. Its processing cost is not high to compare SiC honing stone.Changing the original silicon abrasive to diamond and CBN abrasives, the test results showed the following advantages:1. Long life. Under reasonable conditions of use, using life of honing is 5000-10000 pieces.2. Honing efficient. 60-90seconds/hole.3. To improve the working conditions of workers. Honing can reduce the time to replace and adjust the honing head.4. The precision of production is improved. It is increased more than 30% for II sub-group by the use of diamond honing than SiC honing.The coolant is changed from oil to water-soluble, test results showed the following advantages:1. Oil Base coolant exists the danger of fire, water base coolant has not the problem.2. To reduce the pollution and dirty caused by spread of oil mist which is caused by spattering oil, so as to maintain a clean operating environment occasions. Energy conservation and emission reduction to meet national requirements.3. With no corrosion, pollution-free, in line with environmental protection requirements. There are good lubrication, cleaning and cooling effect. It is more emphasis on its cleansing and cooling effect for super-hard abrasive. 4. Considering the cost, the use of water base coolant has been able to meet the application requirements, and can significantly reduce the cost of coolantIt is studied by Mitsubishi 4G64 engine block manufacturing process in this thesis. The advanced platau honing technology replaced the original general honing process. Improvements and test of the honing machine, verify the advanced nature of the flat roofed honing process. Test results show that the cost, efficiency, and performance of engine has been improved.