Course Design - Water Pump Roll Recovery

Contents

Contents:

1. Introduction... 3 page

2. Initial data 3 pages

3. Selection of the annual production program.... 4 pages

4. Analysis of source data... 4 pages

5.Compile list of possible defects of engine water pump roller 4 pts

6. Punch list composition... 4 pages

7.Recoverable part description (characteristic).... 5 pp

8.Select base surfaces when restoring part surface... 6 pages

9.Compounding the defect recovery route... 6 pages

10. Choosing a rational method of restoring the part.... 7 pages

11. Calculation of cutting modes, time standards, selection of process equipment and cutting tool... 8 pages

12.Normiration15 page

Introduction:

The water pump serves to create water circulation in the forced cooling system. Centrifugal pumps are used for this purpose. At zil130, a water pump, mounted on one fan roller, is located in the upper front part of the engine unit and is driven from the crankshaft by a belt transmission.

The cooling system shall be fully filled with cooling liquid.

If the liquid does not reach 5-7% of the system capacity, it may stop

circulation, which at low temperatures leads to formation, and at

high temperatures to engine overheating. For temperature control

system condition in inlet pipeline cooling jacket is installed

coolant temperature indicator sensor. Cooling liquid from

radiator is supplied via lower branch pipe to one thousand with spacer spring in

water pump from which is supplied to RH and LH flaps via two flaps

cylinder block cooling jackets. And to the cooling jacket, the liquid rises

up and through the channels passing at the outlet valves, enters the jackets

cooling of cylinder heads, from which hot liquid passes into jacket

the inlet pipe of the wire and heats it, providing better conditions

mixing. Then the liquid passes through the thermostat valve and through

the outlet pipe and its hose are returned to the radiator, where heated

the liquid is cooled.

Source Data:

Develop process of water pump roller recovery. 

Select Annual Production Program

Na - annual production program of repair of units or cars, pcs.;

Na = 1600 pcs

 3. Analysis of source data

The water pump serves to create water circulation in the forced cooling system. Centrifugal pumps are used for this purpose.

In most models, a water pump mounted on one fan roller is located at the top of the front of the engine unit and is driven from the crankshaft by belt transmission. The water pump housing serves as a supporting frame for attachment of all parts of the device, including holes for bearings, shafts, bushings.

Structural elements of the part are: housing wall, end faces of bearing sockets, bosses with holes for bolts, end face for thrust washer, grooves for lubrication, internal chamfers.

List of possible defects of the engine water pump roller

1 - surface wear for bearing;

2 - wear of neck under impeller;

3 - slot wear;

4 - thread damage;

Description of the part to be restored (characteristic)

Water pump roller refers to the group nomenclature of class 2 recoverable parts (round rods).

Selecting Datum Surfaces When Restoring a Part Surface

The bases are selected in accordance with GOST 3.110781,

GOST 2149576.

When machining Class 2 parts (round rods), the main base surfaces are center holes and outer cylindrical surfaces.

When restoring the water pump roller, the process bases will be center holes and neck

Installation of cylindrical part in three cam cartridge with stop against end face.

When restoring a part, the base surfaces are used 

surfaces that were basic in the manufacture of this part, but for their reuse it is necessary to assign machining operations aimed at restoring their geometries.

Preparation of defect recovery route

To eliminate each defect of the part, a technological process is developed:

1) Bearing surface wear:

Name and content of the transaction:

Surfacing. and applying a metal layer to the surface of the workpiece or article by melting welding. Weld the worn surface

Turning, turning of the surface - correcting the geometric shape of the roller;

Grinding. Round grinding machine

            ground to nominal size

2) Wear of neck under impeller:

Name and content of the transaction:

Building up

         Weld the worn surface

Turning, turning of the surface - correcting the geometric shape of the roller;

Grinding. Round grinding machine 

         ground to nominal size

3) Slot wear

Name and content of the transaction:

Surfacing. Surfacing apparatus under flux layer A-409

Weld under flux layer followed by milling

Milling: mill to working size

4) Thread damage

            Name and content of the transaction

turning: bore worn thread

Surfacing: build up worn surface

Turning-Bore the surface for thread and then thread

9.Select a rational method for restoring a part.

The choice of the method of restoring the parts depends on their structural and technological features and working conditions, wear, technological properties of the restoration methods themselves, which determine the durability of the repaired parts, and the cost of their restoration and the applicability of the method.

1,2) wear of surface for bearing, wear of neck for impeller;

Wear of surface for bearing up to 16.99 mm and neck for impeller eliminate:

Surfacing is the application of a layer of metal to the surface of a workpiece or article by melting welding.

Chromium plating 

Steeling

with subsequent grinding on lathe to size as per working drawing.

3. slot wear;

Wear of keyway more than 4.08 mm is eliminated by brewing followed by milling for size of working drawing. Welding under flux - A distinctive feature of the process of automatic welding under flux is that the welding arc burns not in the open air, but under a layer of granular bulk flux. Under the action of the heat of the arc, the main metal of the part, the electrode wire and the part of the flux immediately adjacent to the surfacing zone are melted. The electrode wire is fed down into the surfacing zone at its melting rate, melts and passes into the floor in the form of separate drops.

4. thread damage;

Method of metal surfacing reduction in carbon dioxide medium and thread cutting of nominal diameter. Melting of threaded hole by welding with subsequent drilling and cutting of similar thread in the same place. Build-up in carbon dioxide is the cheapest method of build-up and can provide the required hardness up to 300 NV. 

Calculation of cutting modes, time standards, selection of process equipment and cutting tool

Turning - surface turning - correcting the geometry of the roller;

-Selects a cutting tool. Select a pass-through thrust straight cutter with hard alloy plates (T15K6) with an angle in plan 900

(according to GOST 1887973).

-Assigns the cutting depth. In case of rough turning and absence of restrictions on equipment power, stiffness of AIDS system is taken equal to allowance for processing. With the roughness parameter of the surface to be treated, Ra = 3.2 μm inclusive t = 0.5... 2.0 mm. We accept cutting depth t = 0.8 mm.

- Selection of feed. During rough turning, the maximum allowable power of the equipment, the stiffness of the AIDS system, the strength of the cutting insert and the strength of the holder is taken. Select feed s = 0.28 mm/v.