Crankshaft pulley hub

4. Process Part

4.1 Task

Development of assembly sequence of assembly unit (product) and formation of technical requirements for accuracy and quality of elementary surfaces of the part included in this assembly unit; development of part processing sequence.

4.1.1 General description of the project

The technological design should ensure high quality of the product, high labor productivity, low cost, savings of material and energy resources, safety of working conditions.

4.2 Development of assembly sequence of assembly unit (article) and formation of technical requirements for accuracy and quality of elementary surfaces of the part included in this assembly unit

4.2.1 Description of service purpose of assembly unit (article)

Crankshaft pulley serves as driving link in belt drive of water pump and generator. Wedge grooves are made on pulley and mate with belt projections. The unit is installed in the front part of the engine.

4.3.2 Selection of procurement type and its justification

The hub of the crankshaft pulley can be obtained by hot stamping on hammers, achievable accuracy 15... 17 quota.

During hot forging, the metal in the preform is compacted, and the metal fibers are oriented in a certain way, which provides increased strength of the machine parts. In addition, the preform has a higher accuracy than forging, a complex-configuration preform is obtained without undercuts and protrusions interfering with removal from the die, and in addition, the method has a high productivity.

Hardness of forging 156... 229 HV; surface defects up to 0.1mm deep; presence of scale on the surface not more than 10%; stamping slopes are not more than 5ْ

Unlike the finished part, the hub blank does not have holes, chamfers, grooves and radii, there are allowances for machining the surface and the blank has lower surface roughness.

4.3.3 Development of routing process of part manufacturing

4.3.3.1 From the point of view of performing the annual release of the part, the operating process is suitable for processing the crankshaft hub. But in order to improve the quality of processing, we replace the equipment in operations 010, 015 with progressive machines that provide high performance and the required processing accuracy (model 1A240P6 machine is replaced with model 2762 machine). The replacement of the napkin tool introduces progressive tool designs with multi-faceted nontranslatable hard alloy plates with a wear-resistant coating based on titanium carbides and nitrides, while increasing tool resistance 1.52 times. The technical level of production during their implementation increased, firstly, due to the increase in labor productivity, as the downtime of equipment during adjustment was reduced, secondly, due to the improvement in the quality of parts as a result of increased stability of the technological process. Lubricating and cooling liquids (SOFs) play a great role in improving the processing processes and increasing the technical level of production. Treatment is carried out with SOF "Emulsion ET2" - this is an aqueous semisynthetic liquid with higher technological properties and significantly longer service life compared to oil.

We formulate a treatment plan for each elementary surface.

The end face 1 is treated by a 14 KB precision with a roughness Ra of 6.3 μm.

Rough Machining - Turn Preliminary

Finishing - Turn Final

Equipment - lathe semi-automatic 2762

Accessory - cartridge, holder

Cutting tool - T15K6 hard alloy cutter

Measuring tool - brace

Installation bases - by end faces

External cylindrical surface ø59 mm shall be machined according to 14 accuracy range with roughness Ra 6.3 mcm

Rough Machining - Turn Preliminary

Finishing - Turn Final

Equipment - lathe semi-automatic 2762

Accessory - cartridge, holder

Cutting tool - T15K6 cutter

Measuring tool - brace

Installation bases - by end faces

External cylindrical surface ø55 mm is machined as per

8 quantum accuracy with roughness Ra 1.6 μm

Rough Machining - Turn Preliminary

Reroute Processing - Turn Final

Finishing - polishing

Equipment - lathe multithreaded semi-automatic 1N713, special polishing machine VS-22

Accessory - cartridge, holder

Cutting tool - T15K6 cutter, grinding skin

Measuring tool - brace

Installation bases - at the ends, hole

The end face 2 is treated by a 14 KB precision with a roughness Ra of 6.3 μm.

Rough Machining - Turn Preliminary

Finishing - Turn Final

Equipment - lathe semi-automatic 2762

Accessory - cartridge, holder

Cutting tool - T15K6 cutter

Measuring tool - brace, depth meter

Installation bases - by end faces

Hole ø38 mm is processed by 8 kvalitet of accuracy with roughness Ra 1.6 μm

Draft Pretreatment

Finishing-Sweep Final

The equipment - vertically lingering machine 7B66IH059, press and hydraulic C949.

Accessory - cartridge, holder, bushing.

Cutting tool - pulling of P6M5.

Measuring tool - PRNE plug, long-length meter

Installation bases - by end faces

The outer cylindrical surface of 1 ø88 mm is machined according to the 14 accuracy range with roughness Ra 6.3 μm

Rough Machining - Turn Preliminary

Finishing - Turn Final

Equipment - lathe semi-automatic 2762

Accessory - cartridge, holder

Cutting tool - T15K6 cutter

Measuring tool - brace

Installation bases - by end faces

The end face 3 is treated by 14 KB with a roughness Ra of 6.3 μm

Rough Machining - Turn Preliminary

Finishing - Turn Final

Equipment - lathe semi-automatic 2762

Accessory - cartridge, holder

Cutting tool - T15K6 cutter

Measuring tool - brace

Installation bases - by end faces

The end face 4 is treated by a 14 KB precision with a roughness Ra of 6.3 μm.

Rough Machining - Turn Preliminary

Finishing - Turn Final

Equipment - lathe semi-automatic 2762

Accessory - cartridge, holder

Cutting tool - T15K6 cutter

Measuring tool - brace

Installation bases - by end faces

External cylindrical surface ø570.052 mm is machined according to 9 kvalitet of accuracy with roughness Ra 2.5 mcm

Rough Machining - Turn Preliminary

Reroute Processing - Turn Final

Finishing - grinding

The equipment - a turning semiautomatic device 2762, the circular grinding HSh310N27 machine

Accessory - cartridge, holder, semi-center

Cutting tool - T15K6 cutter, grinding wheel.

Measuring tool - brace, caliper

Installation bases - at the ends, hole

A groove Ra of 0.3 mm width of 0.5 mm is sharpened by 14 KB with a roughness Ra of 6.3 μm.

Equipment - lathe multithreaded semi-automatic 1H713

Accessory - collet mandrel, bushing, center.

Cutting tool - T15K6 cutter

Installation bases - end and hole

Keyway slot 8 mm is machined according to 8 qa accuracy with roughness Ra 1.6 μm

Draft Pretreatment

Finishing-Sweep Final

The equipment - horizontally lingering machine 7A510

Accessory - cartridge, holder, bushing.

Cutting tool - pulling of P6M5.

Measuring instrument - gauge, probe

Installation bases - by end faces

The hole ø6.7 mm is processed according to the 14 accuracy quota with roughness Ra 6.3 μm

Draft-Drill

Finishing - countersink, thread cutting.

The equipment is the special modular XA8811 machine

Accessory - conductor plate, bushing, cartridge.

Cutting tool - R6M5 drill, R6M5 countersink, T15K6 trigger.

Measuring tool - threaded plug

Installation bases - at the ends, hole.