Research On Casting Process And Co-line Production Technology Of V-series Diesel Engine Cylinder Block

As one of the power components of large-scale transportation equipment,diesel engine has an indispensable position in the transportation industry because of its good power performance and economy.As the core component of diesel engine,the performance and quality of diesel engine cylinder block is directly related to the use of the entire engine.At present,the production and research of diesel engines mainly focus on exhaust gas control,structural optimization,processing and simulation technology,etc.There are relatively few systematic researches on the cylinder block casting process.In addition,there are more studies on the casting process of a single diesel engine cylinder block,and fewer studies on the commonality of serialized cylinder blocks.There are few common studies on multiple series,casting process design based on common studies,and collinear technology in actual production.In this paper,three typical cylinder blocks(namely,GE320 cylinder,GE420 cylinder and M3020 cylinder)of the three series of V-type diesel engine blocks of the V-type GE3 series,GE4 series and M3020 series are the research objects.Research on material properties,mechanical properties,microstructure and other aspects,summarize the common and individual characteristics of cylinder structure and material properties;carry out the casting process design of "individual optimization based on common feature design" for three typical cylinders,and Numerical simulation of the designed casting process is carried out;finally,the quality of the actual production of the three typical cylinders is tested and researched,and the causes of common defects in the cylinder block casting are studied.At the same time,the quality control methods are proposed and the three are further summarized.The key technology of co-line production of series V-type diesel engine cylinder block casting process.This article finally obtained the following results:(1)The general and individual characteristics of the three series of three typical diesel engine cylinder blocks in terms of their structural features,material properties,mechanical properties and microstructure are studied and summarized.In terms of structural characteristics,the three typical cylinders all show different degrees of common characteristics in terms of main structure and unit structural characteristics;in terms of material characteristics,they all have the "self-feeding ability" of cast iron materials.In terms of performance requirements and microstructure requirements,it shows sufficient individual characteristics.At the same time,combining the different degrees of individual characteristics shown in various aspects,it can be concluded that the three typical cylinder body castings have the main body in terms of structure,material,etc.The commonality determines the consistency of the design ideas of the three typical cylinders in the casting process;the individualized differences in parts or parameters determine the individualized differences in the casting process.(2)Based on the common and individual characteristics of three typical diesel engine cylinder blocks,the design idea of "individual optimization based on common feature design" was proposed,and the casting process design of three typical cylinder blocks was completed.The commonality is embodied in the process principles,design ideas,and main structure of the casting process design,while the individuality is embodied in the design of different parameters and targeted optimization design.Finally,through the numerical simulation of the double filling process and the numerical simulation of the three solidification process of three typical cylinders,it is proved that the casting process designed in this paper satisfies the smooth and full filling layer by layer during the filling process,and the sequential solidification and equilibrium are satisfied during the solidification process.The solidification design goal provides certain data support for the common design and individual optimization of the three typical cylinders.(3)Based on the casting process design scheme of "individual optimization based on common feature design" of the three typical cylinders,the actual production of the three typical cylinders was carried out,and the actual production results were quality tested.It is further confirmed that the common characteristics are caused by structural commonalities and material commonalities,and the individual differences lie in the specific size and parameter differences caused by different structural details,mechanical properties,and microstructure requirements.At the same time,in the actual production quality inspection,the appearance quality,size,composition,mechanical properties and microstructure of the actual product can all meet customer requirements.Therefore,from the perspective of actual production,the feasibility of co-production of the three series of cylinder blocks is confirmed,and practical production experience is provided for the co-line production of 1t~3t V-series diesel engine cylinder blocks.(4)Based on the actual production of three typical cylinders,the causes of defects that often appear in the production process are studied,and quality control methods are proposed.Using metallographic microscopy,scanning electron microscopy and energy spectroscopy and other experimental detection methods,the causes and formation mechanisms of defects are studied,and corresponding actual production control methods are proposed.Furthermore,it summarizes the key technologies of coline production of the three series of V-type diesel engine cylinder blocks in actual production,that is,the actual production co-line technology of process procedures,quality control methods and equipment management.Finally,the large-scale co-line production of three series of V-type diesel engines was realized.