Process of restoration of ZIL-130 cardan shaft cross

Contents

Introduction

1 Recoverable Part

2. Types of wear of the part to be restored

3. Part check

4 Recovery Methods

5 Substantiation of part recovery method selection

6 Process operations for restoration of spikes of cross

7 Selection of equipment, tools, accessories

8 Calculation of part recovery process parameters

9 Determination of cost-effectiveness and recovery efficiency of parts

Conclusion

List of literature used

Introduction

The most important factors affecting the choice of labour organization method are: the scope of work depends on the number, type and operating conditions of cars, the stability of the scope of work for the periods of the year, the number of car repair workers, the level of cooperation to perform these works in the central repair shop, the amount of work performed at car maintenance stations, the presence and state of the production and technical base, the degree of participation of drivers in the performance of these works. But the main requirement for choosing a method of organizing labor is one: it should ensure an improvement in the main indicators.

Such indicators for vehicle maintenance and repair are:

- reduction of car downtime during maintenance and repair;

- lower maintenance and repair costs

But these indicators depend on the quality of performance and the level of use of working time. So, improving the quality of work and improving the use of working time should also be taken into account when evaluating the method of organization of work.

An important reserve for reducing the cost of maintenance is the expansion of specialization and co-operation. At specialized ATMs with mass-flow production, the cost of car maintenance and repair is much lower than at enterprises performing the same services in small quantities. The development of specialization requires the establishment of the most rational cooperative links between enterprises.

The reduction of production costs is ensured primarily by increasing labor productivity. With increased productivity.

Labor costs per unit are reduced, and therefore the specific weight of wages in the cost structure is reduced.

Material costs, as is known, occupy a large share in the structure of the cost of services, so even a small saving of raw materials, fuel and energy in the production of each unit of services in the whole enterprise has a large effect.

Wear and tear types of the part to be restored

The main defects of the crosses are: wear of the end and outer surfaces of the spikes, their cracks and debris.

Wear is most common for crosses and leads to a violation of the performance of cardan transmissions.

Recovery Methods

When deciding whether to choose a rational method of restoring a worn part, it is necessary to recommend a method that ensures the maximum service life of the part, that is, operational reliability, at the lowest cost of restoration, as well as taking into account the production capabilities of the repair plant.

As a defect that will be eliminated in the future, we choose wear on the end and outer surfaces of the studs. There are 3 ways to solve this problem:

-Vibrodugal surfacing.

The advantages of this method are: simplicity, high productivity and economy, the ability to weld parts of small diameters, correct minor deformations of parts due to vibration of the electrode, achieving high hardness of the build-up without subsequent heat treatment.

Disadvantages: reduction of fatigue strength of the restored parts and complexity of subsequent processing. Due to the high gas saturation of the built-up metal, it is not possible to re-deposit by other methods without first completely removing the coating obtained by the vibration-arc method.

-Chroming.

Advantages of the method: simple equipment, strong adhesion to almost all metals, high heat resistance.

Disadvantages: low process performance no more than 0.03mm/h, impossibility of restoring parts with high wear.

- Remaining.

Advantages: the starting materials included in the electrolyte are cheap; the current yield of the metal is 75... 95%; metal deposition rate and coating thickness are significantly higher than in chromium plating; machining of the coating after quenching is carried out under normal cutting modes; the remaining process is easily controlled and can be automated.

Disadvantages: high corrosion activity of the electrolyte; complexity of the process; the need for frequent electrolyte filtration.

Selection of equipment, tools, accessories

Washing is carried out in OM4267 washing machine, in kerosene, and then blown with compressed air.

When analyzing the state of the part, a table for defective ORG14 6801-080 A GOSNITI is used.

Grinding is carried out on round-grinding machine ZM152 of IMF.

Degreasing is carried out by apparatus with solvent. Equipment during installation on the suspension: desktop, cabinet with a set of suspensions.

Decapitation is carried out in a bath for chemical etching.

Chroming is carried out in a chroming bath.

During washing suspension with parts is subjected to washing in baths with running cold and hot water.

Removal of parts: parts are removed from suspension and insulation is removed from them. These works are carried out on the mounting table.

tempering for internal stress relief is carried out in electric oil baths.

Grinding is carried out on round-grinding machine ZM152 of IMF.

Control operation is performed by magnetic flaw detector.

Conclusion

In this calculation and graphic work, an analysis of the given part - the cross of the ZIL130 cardan shaft was carried out with subsequent detection of defects. As a result, I proposed ways to repair faults, as well as a complete calculation of one defect, namely: wear of the end and outer surfaces of the spikes, according to which I proposed a chroming method, as a restoration method. From the ratio of prices of new and restored parts, it is obvious that restoring the defective part of the part in the proposed way is cost-effective than buying a new part on the market.

In performing the work, we fixed and applied the knowledge on the course of the subject Technology of restoration of machine parts and equipment of the industry, learned to compile a roadmap and find many recovery methods and choose among them the most expedient and economically profitable.

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