The Design Of Differential Shells' Remanufacturing Production Line Based On Surfacing

Remanufacturing is the important part and the developing direction of advanced manufacturing technologies in the environment of energy conservation for its great resource potential, notable economic benefits and obvious environmental effects. Differentials are one of the important parts of construction machineries, and the differential shells are one of parts with remanufacturing value for their complex structures, high precision, great difficulty of manufacturing and high price. Due to the terrible and complex working environment of construction machineries, the main parts will be worn out, bumped, broken and become invalid. The study found that the main failure mode of the differential shells is abrasion, and the worn position is on the mounting surface which contacts with the side gear. The worn shells still remain life, and the size of worn position can be restored by some feasible remediation methods to give new properties to the surface, such as surface engineering technologies. So we use surfacing technology to remanufacture differential shells and design a high efficiency, automatic production line for restoring shells' worn surface. This production line certainly has great practical significance to replace manual operations, reduce labor intensity, improve production efficiency, achieve mass production, reduce production costs and promote the development of remanufacturing.The paper starts from the analysis of productions' failure modes, and determines the remanufacturing program with laser cold welding technology to restore the worn surface according to the differential shells' failure characteristics. And then designing a special remanufacturing production line for restoring the differential shells' abrasion. In order to make the design combining with actual production better, the paper designs the workshop process, layouts the workshop, designs main processes such as dismantling, cleaning, detecting, restoring according to the requirements of remanufacturing production processes, and selects appropriate technical methods and production equipments for them. It places great emphasis on dismantling, welding and transporting and designs the dismantling machine, automatic welding machine and roller conveyor for meeting these processes' demands. In order to ensure the rationality and reliability of the dismantling process, we use the principles and methods of value engineering to optimize the dismantling machine's fixture. We improve the structure of existing fixture by means of functional analysis to improve function, cut costs and meet the demands of dismantling process better.