CN103433708A - Method for manufacturing turbocharger box body of high-speed train head - Google Patents
Method for manufacturing turbocharger box body of high-speed train head Download PDFInfo
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- CN103433708A CN103433708A CN2013103811846A CN201310381184A CN103433708A CN 103433708 A CN103433708 A CN 103433708A CN 2013103811846 A CN2013103811846 A CN 2013103811846A CN 201310381184 A CN201310381184 A CN 201310381184A CN 103433708 A CN103433708 A CN 103433708A
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Abstract
The invention provides a method for manufacturing a turbocharger box body of a high-speed train head. The turbocharger box body comprises a gas compressor bearing end face and a turbine end face. The gas compressor bearing end face is provided with gas compressor end holes, and the turbine end face is provided with turbine end holes. The method includes the steps of clamping the turbocharger box body on a numerically-controlled machine tool to carry out machining, wherein the machining includes the process of box body rough machining, stress relief, semifinishing, finish machining and detecting. The method is characterized in that in the finish machining process, a linear amplification proportion method combining with a least squares fit mode is adopted, and the method specifically includes the steps of calculating magnification times of parts in the detecting process according to a three-coordinate precision detection method, that is, the coaxiality precision needs to be decreased by a certain multiple, and then supplementing sufficient capacity of equipment through the least squares fit technology. The turbocharger box body manufactured through the method is high in precision, good in deformation resistance effect, good in sealing performance, and capable of meeting the requirements of high-speed rails and replacing imported products.
Description
Technical field
The present invention relates to a kind of turbocharger of train, particularly the manufacture method of the headstock turbocharger of a kind of high accuracy, high leakproofness.
Background technology
" planning of Chinese Railway Long-and Medium-term Development " according to new adjustment, to the year two thousand twenty, for meeting the passenger transport demand of rapid growth, set up the Planning of Express Passenger Corridor between provincial capital and big and medium-sized cities, planning " four vertical four horizontal strokes " railway Planning of Express Passenger Corridor and three intercity personal rapid transit systems.Build the personal rapid transit special line more than 1.6 ten thousand kilometers.
Expect the year two thousand twenty, the high speed railway construction mileage of 200 kilometers, China and above speed per hour will, over 1.8 ten thousand kilometers, will account for the over half of world's high-speed railway total kilometrage.
The casing of the turbo-charger sytem used on bullet train (being the headstock booster casing of this patent) is although be a kind of parts relatively simple for structure, but because the turbocharger box shape size of high speed motor car is larger, the required precision of part is higher, particularly axiality, require ￠ 0.0127 mm.Domestic machining factory is mainly automobile now provides the turbocharger casing, because automobile is less by turbocharger box shape size, processing and manufacturing requires difficult point relatively low, so the working axiality precision of the turbocharger casing of producing generally between ￠ 0.03mm ~ ￠ 0.05mm, the requirement that does not reach bullet train far away.Trace it to its cause, also because the required precision that the machine finish grade of domestic enterprise does not reach Project Product at present at all.
Summary of the invention
The object of the invention is to invent a kind of manufacture method of a kind of bullet train headstock turbocharger casing completely newly, by the control to processing technology, produce the high accuracy that precision meets the High-sped Trains requirement, the headstock turbocharger casing of high-axiality.
The present invention is a kind of manufacture method of bullet train headstock turbocharger casing, described turbocharger casing, contain compressor bearing face and turbine end face, have the compressor stomidium on the compressor bearing face, the turbine end face has the turbine stomidium, the machined on Digit Control Machine Tool of described casing clamping, its manufacture method, comprise casing roughing, Stress Release, semifinishing, the process of fine finishining and detection, it is characterized in that, accurately machined the time, adopt the method for linear magnification ratio in conjunction with least square fitting, specifically: according to the detection method of three-dimensional, calculate the multiplication factor of part when detecting, be that coaxial accuracy will dwindle certain multiple, then carry out again the scarce capacity of compensation equipment by Least-square fitting method.
Preferred multiplication factor is 6 times.
Three concrete coordinate detection methods are:
1, adopt cmm chaining pin bulb to be surveyed, at first on the compressed air bearing end face of turbine casing, get 4 points, compressor stomidium centre position is got at 4 and is got circle, sets up thick benchmark;
2, to get at 12 at the first-class distributing position of compressor bearing face and set up coordinate plane, in the compressor stomidium, x=0.75 inch position is got at 6 and is got circle, sets up and measures coordinate system-1;
3, in coordinate system-1 time, get three circles at compressor end x=0.077 inch, x=0.7 inch, x=1.1 inch respectively, be defined as circle-A, circle-B and circle-C;
4, with circle-A, circle-B and circle-C matching cylinder-1;
5, cylinder-1 center line of take is primary standard, and cylinder-1 center line and compressor bearing face intersection point are coordinate zero point, sets up and measures coordinate system-2;
6, in coordinate system-2 time, get three circles at compressor end x=0.077 inch, x=0.7 inch, x=1.1 inch respectively, be defined as circle-1, circle-2 and circle-3;
7, in coordinate system-2 time, get three circles at turbine end x=6.8 inch, x=7.2 inch, x=7.75 inch respectively, be defined as circle-4, circle-5 and circle-6;
8, fit to cylinder-2 with circle-1, circle-2 and circle-3;
9, take cylinder-2 to estimate respectively and circle-4, circle-5 and circle-6 axiality as benchmark.
This method of the present invention, can on existing lathe, process the turbocharger casing of the high accuracy, the particularly high-axiality that meet the high ferro requirement, can reduce production costs, improve the qualification rate of product, improve railroad traction product quality and service life, can replace imported, promote the development of China railways railroad traction industry.
The accompanying drawing explanation
Fig. 1, the structure of the turbocharging casing that the inventive method is manufactured.
Fig. 2, manufacturing flow chart of the present invention.
Fig. 3, the schematic diagram of setting up the coordinate system-1 of coaxality measurement of the present invention.
Fig. 4, the schematic diagram of setting up the coordinate system-2 of coaxality measurement of the present invention.
Fig. 5, the schematic diagram of the evaluation procedure of axiality of the present invention.
The specific embodiment
As Fig. 1, the turbocharger casing of this high-speed train headstock of manufacturing of the present invention, its structure mainly includes compressor bearing face 1 and the turbine end face 2 at two, has compressor stomidium 3 on compressor bearing face 1, and turbine end face 2 has turbine stomidium 4.The requirement of described axiality is exactly the axiality in these two holes, requirement according to bullet train, the axiality needed is ￠ 0.0127 mm, the long-play deformation under the motor-car high-speed and high-temperature of part ￠ 60--￠ 60.013mm dead eye is less than 0.015, and this just requires within the deformation quantity of part in process be controlled at the 0.01mm scope.
The process of whole processing method is as the flow chart of Fig. 2, concrete steps are: at first carry out casing roughing, and release casing internal stress, then carry out secondary roughing, wherein need to control casing allowance, the wait thermal deformation is weathering, then carries out semifinishing and fine finishining, wherein needs to control the machining accuracy of casing; Fine finishining reaches designing requirement later, carries out three check of coordinate precision quality and airtight checks, qualified packed products later.
one. solved distortion in the part process impact on axiality by following 12 steps
A. control the flatness of part processing locating surface in 0.01mm;
B. control the flatness of frock and workpiece location contact-making surface in 0.01mm;
C. reduce workpiece and frock contact area, reduce the frock manufacture difficulty, reduce clamping deformation;
D. the method that increases rebound shifts distortion;
E. stipulate the locking torsion of part, confirm with torque spanner, reduce or while eliminating operative employee's clamping due to the clamping deformation of generation accidentally;
F. before Finishing Parts Machining, with scale, be supported on loose pressing plate on workpiece, then compress three less points of distortion, reduce or eliminate to press-fit distortion;
G. strictly control between numerical control lathe 20 ° ± 2 ° of temperature;
H. before processing, part is put into constant temperature between numerical control lathe in advance in 6 hours;
I. the semifinishing cutter is selected sharp coated cemented carbide insert, controls allowance for finish at 0.06 ~ 0.1mm;
J. finishing tool is selected cubic boron nitride blade (CBN blade), controls finishing size;
K. select cutter and the little blade of nose angle that knife bar is sturdy as far as possible, reduce the cutter that shakes;
L. adopt the center cutter water outlet, iron powder on point of a knife etc. is rinsed well, reduce the heat in metal cutting of blade simultaneously.
two. after having solved the train high-speed cruising by following four steps, under high temperature, deform on the impact of axiality
A. part made allowance before fine finishining is eliminated part stress at 2 ~ 3mm;
B. part is incubated 12 hours under 250 ° ± 5 ° states, eliminates part stress;
C. the part semifinishing that tries again before fine finishining, stay the monolateral 0.2 ~ 0.25mm of being of allowance;
D. semifinishing is complete, and it is weathering that the part placement is done stress in 3 ~ 4 days.
three. the machining accuracy of this patent is controlled
What adopt is the method for linear magnification ratio in conjunction with least square fitting, and the equipment of preparation has NHC-8106 three-coordinates measuring machine and Digit Control Machine Tool, tool setting gauge etc., uses Digit Control Machine Tool processing.Calculate the multiplication factor (detection method determine multiplication factor just determine) of part when detecting according to the detection method of three-dimensional, be that coaxial accuracy ￠ 0.0127 mm will dwindle 6 times on this basis, be 0.0127/6=0.0021, this just requires the perpendicularity of the Z axis of lathe and X, Y-axis to be less than 0.002, and the accuracy class of lathe is at 0.005 ~ 0.01mm basically at present, still can not meet requirement on machining accuracy; Then carry out again the scarce capacity of compensation equipment by Least-square fitting method, guarantee stability and the efficiency of part processing, can be stable meet this specification requirement.
The process of concrete process as shown in Fig. 3 ~ 5:
As shown in Figure 3:
1) adopt cmm chaining pin bulb to be surveyed, cmm chaining pin bulb diameter 5mm, application standard ball sizing cmm equipment before the test of every day is at first got 4 points on the compressed air bearing end face 1 of turbine casing, compressor stomidium 3 centre positions are got at 4 and are got circle, set up thick benchmark;
2) get at 12 at the first-class distributing position of compressor bearing face 1 and set up coordinate plane, the interior x=0.75 inch of compressor stomidium 3 position is got at 6 and is got circle, sets up and measures coordinate system-1;
As shown in Figure 4:
3) in coordinate system-1 time, get three circles at compressor end x=0.077 inch, x=0.7 inch, x=1.1 inch respectively, be defined as circle-A, circle-B and circle-C;
4) fit to cylinder-1 with circle-A, circle-B and circle-C;
5) take cylinder-1 center line is primary standard, and cylinder-1 center line and compressor bearing face 1 intersection point are coordinate zero point, sets up and measures coordinate system-2;
As shown in Figure 5:
6) in coordinate system-2 time, get three circles at compressor end x=0.077 inch, x=0.7 inch, x=1.1 inch respectively, be defined as circle-1, circle-2 and circle-3;
7) in coordinate system-2 time, get three circles at turbine end x=6.8 inch, x=7.2 inch, x=7.75 inch respectively, be defined as circle-4, circle-5 and circle-6;
8) fit to cylinder-2 with circle-1, circle-2 and circle-3;
9) take cylinder-2 estimates respectively and circle-4, circle-5 and circle-6 axiality as benchmark.
the key technical indexes of the present embodiment:
Endoporus (through hole): ￠ 60--￠ 60.013mm, hole is long: 200mm, axiality: ￠ 0.0127mm;
Large plane and endoporus: ￠ 60--60.013mm, the perpendicularity of axis: 0.05mm;
Hole ￠ 184mm and endoporus ￠ 60--￠ 60.013mm axiality: ￠ 0.05mm, measure evaluation length: 40mm;
The perpendicularity of endoporus ￠ 60--￠ 60.013mm end face and endoporus: 0.025mm, the measurement evaluation length is 200mm;
Return the perpendicularity of reverse side endoporus ￠ 60-￠ 60.013mm end face and endoporus after turnback: 0.025mm, the measurement evaluation length is 260mm;
The axiality of stepped hole ￠ 240 and endoporus ￠ 60--￠ 60.013mm: ￠ 0.025mm, the measurement evaluation length is 270mm;
The axiality of endoporus ￠ 432mm and endoporus ￠ 60--￠ 60.013mm: ￠ 0.05mm, the measurement evaluation length is 392mm;
The axiality of cylindrical ￠ 509-￠ 509.05mm and endoporus: ￠ 0.076mm, the measurement evaluation length is 392mm.
four. part is done air seal test: turbine casing performing leak test
1) daily calibration 37.5Nm and 200Nm torque spanner, detect and record result online;
2) two suspension ring of dismantling turn to turbo-side upwards by the turbine casing on rubber blanket, and then dismantle suspension ring and suspender, install two rotating hoisting rings at turbine end face TIR screwed hole, and the turbine casing is winched on workbench;
3) water channel sealing:
A) alcohol is cleaned two water cavity cover plates, first at water cavity cover plate pad, simultaneously avoids installing hole and smears uniformly Permatex 80017 fluid sealants, then the one side of gluing is bonded on the water cavity cover plate, then smears the another side of pad;
B) with air gun, blow off in bolt mounting holes and water channel in ponding;
C) on the screw thread of cover plate set bolt, smear micro-five generation diesel engine lubricating oil, two water cavity cover plates that glue pad are arranged on the turbine casing with bolt L14AP19030 and spring washer L401P28, and tighten with the 37.5Nm moment of torsion, bolt head is drawn white marking;
D) smear happy safe 542 fluid sealants and install at the stifled N5722P93 screw thread of water channel place, tightening with the 200Nm moment of torsion, drawing white marking;
E) the bottom seal plate is installed, guarantees that O type circle has been arranged on seal plate and clean free from smutting during;
F) spraying Spray lube A on the O type circle of intake valve and Pressure gauge mounting flange, install to respectively the casing watercourse port to intake valve and Pressure gauge;
4) critical process, connect compressed air hose, and the gas (can not surpass 1.0MPa) to injecting 0.8MPa pressure in the casing water cavity, then disconnect air pipe line.Casing is winched in tank and be immersed in the water (air inlet pipe and Pressure gauge can not be immersed in the water) fully, observe and within least 15 minutes, see if there is bubble appearance, pressure decreased phenomenon, this process water temperature must be controlled at 50-55 ° of C;
?the thin liquid of releasing that solution in tank is 03-XF antirust agent, its related request is as follows:
A) configuration: antirust agent fully shakes up in pail pack, by 10% volume ratio, is added to the water and releases rare mixing;
5) workpiece is hung out from tank, be parked in the tank top and discharge ponding, use pressure-air that the water remained in casing is cleaned out;
6) casing is winched on workbench, emit the gas in water cavity, the intake valve of the seal plate of dismantling and watercourse port, Pressure gauge, clean watercourse port flange face and cabinet base face with rag.Check the external sight of turbine box, and the turbine casing is cleaned out;
7) inject CRC 3-36 antirust oil in oil duct and airtight road;
8) lifting turbine casing is to the protection flat board of bearing erecting bed position, takes off turbine casing hang oneself tool and suspension ring.
So far, the process that the present invention manufactures the turbocharger casing all completes, the turbocharger casing precision of manufacturing is high, particularly axiality can reach ￠ 0.0127 mm, and good seal performance, can meet the performance requirement of high-speed railway locomotive, import substitutes, cost is low, easy to process, and yield rate is high.
Claims (6)
1. the manufacture method of a bullet train headstock turbocharger casing, described turbocharger casing, contain compressor bearing face (1) and turbine end face (2), have compressor stomidium (3) on the compressor bearing face, the turbine end face has turbine stomidium (4), the machined on Digit Control Machine Tool of described casing clamping, its manufacture method, comprise casing roughing, Stress Release, semifinishing, the process of fine finishining and detection, it is characterized in that, accurately machined the time, adopt the method for linear magnification ratio in conjunction with least square fitting, specifically: according to the accuracy checking method of three-dimensional, calculate the multiplication factor of part when detecting, be that coaxial accuracy will dwindle certain multiple, then carry out again the scarce capacity of compensation equipment by Least-square fitting method.
2. the manufacture method of bullet train headstock turbocharger casing according to claim 1, is characterized in that, described three coordinate detection methods are:
1, adopt cmm chaining pin bulb to be surveyed, at first on the compressed air bearing end face of turbine casing, get 4 points, compressor stomidium centre position is got at 4 and is got circle, sets up thick benchmark;
2, to get at 12 at the first-class distributing position of compressor bearing face and set up coordinate plane, in the compressor stomidium, x=0.75 inch position is got at 6 and is got circle, sets up and measures coordinate system-1;
3, in coordinate system-1 time, get three circles at compressor end x=0.077 inch, x=0.7 inch, x=1.1 inch respectively, be defined as circle-A, circle-B and circle-C;
4, with circle-A, circle-B and circle-C matching cylinder-1;
5, cylinder-1 center line of take is primary standard, and cylinder-1 center line and compressor bearing face intersection point are coordinate zero point, sets up and measures coordinate system-2;
6, in coordinate system-2 time, get three circles at compressor end x=0.077 inch, x=0.7 inch, x=1.1 inch respectively, be defined as circle-1, circle-2 and circle-3;
7, in coordinate system-2 time, get three circles at turbine end x=6.8 inch, x=7.2 inch, x=7.75 inch respectively, be defined as circle-4, circle-5 and circle-6;
8, fit to cylinder-2 with circle-1, circle-2 and circle-3;
9, take cylinder-2 to estimate respectively and circle-4, circle-5 and circle-6 axiality as benchmark.
3. the manufacture method of bullet train headstock turbocharger casing according to claim 1, is characterized in that, the multiplication factor of setting in described testing process is 6 times.
4. the manufacture method of bullet train headstock turbocharger casing according to claim 1, is characterized in that, described clamping on Digit Control Machine Tool adopts following measures:
A. control the flatness of part processing locating surface in 0.01mm;
B. control the flatness of frock and workpiece location contact-making surface in 0.01mm;
C. reduce workpiece and frock contact area, reduce the frock manufacture difficulty, reduce clamping deformation;
D. the method that increases rebound shifts distortion;
E. stipulate the locking torsion of part, confirm with torque spanner, reduce or while eliminating operative employee's clamping due to the clamping deformation of generation accidentally;
F. before Finishing Parts Machining, with scale, be supported on loose pressing plate on workpiece, then compress three less points of distortion, reduce or eliminate to press-fit distortion;
G. strictly control between numerical control lathe 20 ° ± 2 ° of temperature;
H. before processing, part is put into constant temperature between numerical control lathe in advance in 6 hours;
I. the semifinishing cutter is selected sharp coated cemented carbide insert, controls allowance for finish at 0.06 ~ 0.1mm;
J. finishing tool is selected cubic boron nitride blade (CBN blade), controls finishing size;
K. select cutter and the little blade of nose angle that knife bar is sturdy as far as possible, reduce the cutter that shakes;
L. adopt the center cutter water outlet, iron powder on point of a knife etc. is rinsed well, reduce the heat in metal cutting of blade simultaneously.
5. the manufacture method of bullet train headstock turbocharger casing according to claim 1, is characterized in that, the described operation that eliminates stress, and the method comprised is:
1) part made allowance before fine finishining is eliminated part stress at 2 ~ 3mm;
2) part is incubated 12 hours under 250 ° ± 5 ° states, eliminates part stress;
3) the part semifinishing that tries again before fine finishining, stay the monolateral 0.2 ~ 0.25mm of being of allowance;
4) semifinishing is complete, and it is weathering that the part placement is done stress in 3 ~ 4 days.
6. the manufacture method of bullet train headstock turbocharger casing according to claim 1, is characterized in that, described detection operation comprises turbine casing performing leak test, and concrete steps are:
1) daily calibration 37.5Nm and 200Nm torque spanner, detect and record result online;
2) two suspension ring of dismantling turn to turbo-side upwards by the turbine casing on rubber blanket, and then dismantle suspension ring and suspender, install two rotating hoisting rings at turbine end face TIR screwed hole, and the turbine casing is winched on workbench;
3) water channel sealing:
A. alcohol is cleaned two water cavity cover plates, first at water cavity cover plate pad, simultaneously avoids installing hole and smears uniformly Permatex 80017 fluid sealants, then the one side of gluing is bonded on the water cavity cover plate, then smears the another side of pad;
B. with air gun, blow off in bolt mounting holes and water channel in ponding;
C. on the screw thread of cover plate set bolt, smear micro-five generation diesel engine lubricating oil, two water cavity cover plates that glue pad are arranged on the turbine casing with bolt L14AP19030 and spring washer L401P28, and tighten with the 37.5Nm moment of torsion, bolt head is drawn white marking;
D. smear happy safe 542 fluid sealants and install at the stifled N5722P93 screw thread of water channel place, tightening with the 200Nm moment of torsion, drawing white marking;
E., the bottom seal plate is installed, guarantees that O type circle has been arranged on seal plate and clean free from smutting during;
F. spraying Spray lube A on the O type circle of intake valve and Pressure gauge mounting flange, install to respectively the casing watercourse port to intake valve and Pressure gauge;
4) critical process, connect compressed air hose, to injecting the gas (can not surpass 1.0MPa) of 0.8MPa pressure in the casing water cavity, then disconnect air pipe line, casing is winched in tank and be immersed in the water (air inlet pipe and Pressure gauge can not be immersed in the water) fully, observe and within least 15 minutes, see if there is bubble appearance, pressure decreased phenomenon, this process water temperature must be controlled at 50-55 ° of C;
The thin liquid of releasing that solution in tank is 03-XF antirust agent, its related request is as follows:
Configuration: antirust agent fully shakes up in pail pack, by 10% volume ratio, is added to the water and releases rare mixing;
5) workpiece is hung out from tank, be parked in the tank top and discharge ponding, use pressure-air that the water remained in casing is cleaned out;
6) casing is winched on workbench, emit the gas in water cavity, the intake valve of the seal plate of dismantling and watercourse port, Pressure gauge, clean watercourse port flange face and cabinet base face with rag, checks the external sight of turbine box, and the turbine casing is cleaned out;
7) inject CRC 3-36 antirust oil in oil duct and airtight road;
8) lifting turbine casing is to the protection flat board of bearing erecting bed position, takes off turbine casing hang oneself tool and suspension ring.
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| CN106624615A (en) * | 2016-10-17 | 2017-05-10 | 上海晋拓金属制品有限公司 | Machining method for motor casing of washing machine |
| CN107796564A (en) * | 2017-11-24 | 2018-03-13 | 苏州富强科技有限公司 | A kind of enclosed mechanism for air tightness detection equipment |
| CN109732279A (en) * | 2018-12-27 | 2019-05-10 | 宁德职业技术学院 | A kind of processing method of massage armchair turbine box |
| CN114770053A (en) * | 2022-05-25 | 2022-07-22 | 常州宝菱重工机械有限公司 | Welding process of ESP continuous casting stainless steel crystallizer water tank |
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| CN103433708B (en) | 2015-11-18 |
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