Course project on the development of the repair process for the rear differential cup of the ZIL-130 car.

Introduction

As practice shows, the prospect of restoring parts exists, despite the prevailing opinion in society "it is easier and cheaper to buy a new spare part than to restore the old one." Modern technologies allow you to ensure the resource of repaired parts, reaching the resource of new ones, and sometimes surpassing it, especially with the current quality of spare parts that are on sale. In addition, the constant increase in prices for new parts makes you think about restoration, in addition, with a properly designed recovery process, the cost of repaired parts is much lower than the cost of new ones. The development of the technological process is complicated by the fact that the volume of repairs has decreased tenfold and relatively small enterprises or workshops working on individual orders are engaged in this. But the design of the recovery process remained a necessary link in the repair.

The purpose of the process design is to establish the optimal sequence and methods of processing individual surfaces and the entire part, to select the necessary equipment, equipment and tools for processing and control of parts, to determine the optimal modes and technical standards of time for the work. The main requirement for part recovery technology is to ensure the required level of service properties of parts at the specified labor productivity with the lowest costs

Source Data

1.1Participation of the part

Part: right differential box bowl

Part No. 130-2403018

Differential cup or housing - its main purpose is to transmit torque from the main gear to the semi-axial gears through the satellites. Inside it are axes for rotation of satellites.

On the ZIL130 car, a gear differential is used, which consists of a cross, bevel gears, semi-axial gears and a box. Satellites are freely fitted on cylindrical pins of cross-piece. The spider, together with the satellites, is fixed in the differential box and rotates with it. Satellites are in constant engagement with gears of RH and LH semi-axes. It is located in the crankcase of the rear axle reduction gear box.

The cup of the differential box of the car ZIL130 is made of Steel st.45, GOST 38060.

During operation of the vehicle, the part is subjected to variable and vibration loads. Impact loads may also occur. Temperature range of part operation 30... + 80 ° С. The high operating temperature of the part is due to the fact that the cup is in direct contact with the lubricant, which during operation is heated to high temperatures. The environment in which the part operates is aggressive (presence of lubricant).

During operation, the cup has the following defects:

- wear of journals for differential bearing;

- wear of holes for trunnion of semi-axle gear;

- wear of the face of the surface for the washer of the axle gear;

- wear of spherical surface for pinion washers;

- wear of holes for spikes of cross-piece;

Process Documentation

2.3.1 Repair Roadmap

The Repair Roadmap (MK) is designed to describe the process, including control and movement for all operations, in the process sequence and is used in production planning. The content, progress of the operation and information on the used equipment and equipment are introduced from the previously completed points of the course project.

2.3.2 Operating card

The Repair Operating Map (OC) is intended to describe operations with indication of transitions and information on process equipment and machining modes.

Safety precautions during repair works

General Occupational Safety Requirements

Persons whose age complies with the established legislation, who have undergone a medical examination in the established manner and who do not have contraindications to the performance of this type of work, who have the appropriate qualifications and are allowed to work independently on machines in the established manner are allowed to perform the work.

Before admission to independent work, the worker undergoes an internship for 2-14 shifts (depending on the nature of the work, the qualification of the employee) under the guidance of a specially appointed person. The worker performing work on metalworking machines shall have an electrical safety group of at least 2. The worker performing work on metalworking machines shall:

Know the requirements set out in the instructions (passports) of the equipment manufacturers and safety instructions;

Use personal protective equipment issued in accordance with standard industry standards, free of charge to workers and employees of special clothing, special shoes and other personal protective equipment:

Suit x/b mi - 12 months.;

Headgear - 12 months.;

Leather boots with a protective sock - 12 months.;

Protective glasses or protective faceplate - before wear;

Be able to provide pre-medical care to the victim;

Comply with internal labor regulations;

Have a clear understanding of hazardous and harmful production factors associated with the performance of work and know the main ways to protect against their impact: insufficient illumination of the working area, increased or reduced air temperature of the working area, increased concentration of harmful substances in the air of the working area, sharp edges, burrs and roughness of tools and equipment, moving and rotating mechanisms and equipment.

Every accident at work shall immediately be reported by the victim or eyewitness to the immediate supervisor, who shall:

Organize first aid for the victim and his delivery to the medical center;

Report the incident to the head of the unit;

Keep the situation at the workplace and the condition of the equipment as they were at the time of the incident until the commission of inquiry begins, if this does not threaten the life and health of the surrounding workers and does not lead to an accident.

The worker must inform the direct work manager about all the equipment, tools and accessories defects noticed and do not start work until they are eliminated.

A worker who appears at work while drunk, in a state of drug or toxic intoxication is not allowed to work on this day (shift).

Occupational Safety Requirements Before Commencement

The organization of the workplace working on metal working machines should ensure the safety of the work. The workplace and its passages must be kept clean, not cluttered with parts, blanks, metal waste. At the workplace, the machine shall have an instruction for an och wound. Hazardous parts of metalworking machines shall be coloured and marked with a safety sign. The moving parts of the metalworking machines, which are a possible source of injury hazard, must be protected or arranged so that the working machine can not touch them or other means preventing injury are used. Protective devices must not limit the machine's technological capabilities and cause inconvenience during operation, cleaning, adjustment and lead to contamination of the lubricant and cooling liquid when opened. If necessary, they are equipped with handles, brackets for easy opening, closing, removal, movement and installation.

During preparation of metalworking machine the worker must check availability and serviceability of:

Protective devices of moving parts of the machine (belt, chain, gear, etc.);

Enclosing devices of current-carrying parts of the machine;

Grounding devices;

Devices for fixing the cutting tool;

Measuring, fastening tools and accessories;

Safety devices for protection against chips, lubricating and cooling liquids.

Occupational safety requirements during operation

The following general safety requirements shall be observed when performing cold metal machining at metalworking machines:

Workpieces or parts to be machined shall be securely secured;

Install and attach the machined part, accessories and tools on a fully stopped machine;

Do not take or supply any items through the operating machine, do not tighten bolts, nuts and other connecting parts of the machine. Do not roll on the machine, do not put on it tools, blanks, products, etc.;

Monitor the timely removal of chips from the workplace and machine. Do not remove chips from the machine directly with hands and tools, use special hooks and brush marks for this.

The worker shall stop the machine and disconnect from the supply mains with a manual lead-in switch located in a safe, serviceable location in the following cases:

Termination of power supply;

Interruptions in operation;

Detection of equipment malfunction;

Fixing or setting on the rate of the machined part, measuring and removing it;

Occurrence of vibration;

Tightening of bolts, nuts and other connecting parts of the machine;

Cleaning and lubrication, cleaning of sawdust and chips;

Operation of the electric motor for two phases (humming), breaking of the grounding wire.

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Occupational Safety Requirements at Work Completion

Upon completion of work, the worker shall:

Shut down the machine and de-energize the electrical equipment;

Remove chips and metal dust from the machine;

Lubricate the rubbing parts of the machine;

Carefully fold finished parts and blanks;

Put in order the workplace (assemble hand tools and protective devices, put them in order and remove them to the allotted place; wiping materials used, folded into metal boxes);

Warn about all detected malfunctions of the replacement, and during one-time work - the direct work manager;

Remove work clothes and special shoes in a specially designated place.

Safety requirements in emergency situations

The worker performing the work shall stop performing the work at:

Fire occurrence near the work site;

Accident;

In case of fire near the work site, the worker shall:

Take measures to de-energize electrical equipment;

Take measures to eliminate the fire with available fire extinguishing equipment. Do not use foam fire extinguishers and water to extinguish the fires of electrical installations and cables under voltage;

If it is impossible to eliminate the fire on your own, inform the direct work manager and call the fire department.

In case of an accident (injury, poisoning, burn, sudden illness, electric shock), the worker is obliged to provide pre-medical assistance to the victim.

Design Section

4.1 Purpose and arrangement of the accessory

The fixture consists of a body 2 which is mounted on the machine table. Inside the housing there is a pneumatic cylinder 3 which is installed on the base 1. The base is attached to the housing by bolts (7). Movement of pneumatic cylinder piston during clamping and pressing of blank is performed by compressed air, which is supplied to pneumatic cylinder through special cavity .

Cup of differential is installed by treated surface of flange on constant support (centering) 9 so that axes of drilled holes are located vertically, corresponding to direction of working feed of drill. After being fixed in this position, an overhead conductor 5 is installed on the blank. In the overhead conductor there are holes into which conductor bushings 8 are pressed. The conductor is pressed from above by quick-change washer 17 and nut 10. Then there is clamp by supply of rod of pneumatic cylinder 4. Handles 12 are provided in the conductor. To remove the accessory from the machine table on the surface of the housing there are eye-bolts 13.

Thus, by using this device, the maximum effect of machining the holes is achieved.