| Piston is the core part of diesel engine,which works in high temperature,high speed,heavy load and poor lubrication condition.With the development of desel engine,the requirement of light material and service life would be higher.The aluminum alloy piston with cast iron insert combines the advantage of high temperature and wear resist of cast iron,and light of aluminum alloy.CW200 diesel engine was developed by Wechai power Corporation,and CSR Qishuyan Institute developed the aluminum alloy piston with cast iron insert for Wechai.Al-Fe bonding area is the key part of the piston,which is related with the reliability of the piston.During the process of trial production,there are 4 quality issues such as gaps and holes exist in the bonding area,the bonding rate is not qualified,new gaps appear after bonding area turing,the roughness of bonding area is not qualified after machining.Improving the piston's Al-Fe manufacturing quality is the main research object of the study.On the basis of reviewing the previous casting,heat treatment and machining process,the study focus on the technical process related with Al-Fe bonding area's quality,including the description and theoretical analysis on the 4 quality issues,doing the cutting experiment on the bonding area to explore more appropriate machining parameters.The paper proposes the optimized technical process for increasing the bonding rate,decreasing the cutting force during turing the bonding area,decreasing the surface roughness after turning the bonding area.The optimized technical process includes cast iron insert aluminizing process optimization,new cutting tool selection and cutting parameters optimization.Moreover,the verification experiment of the optimized technical process was finished.The experiment results show the 4 quality issues of bonding area are resolved,and the products could meet the specification.In the volume production,the qualification rate and volume delivered capacity increase,while manufacturing cost is reduced. |
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