RECOVERY OF CAR ZIL-431410 CRANKSHAFT PULLEY

Contents

Introduction

1 Process Part

Structural features and working conditions of the part

1.2 Part Repair Drawing

1.3 Process Requirements for Defects

1.4 Causes of defects

1.5 Calculation of part lot size

1.6Selection of rational repair method

1.7 Repair Process

1.8 Calculation of time standards for mechanical operation

1.9 Calculation of time standards for repair operation

2 Design part

2.1 Purpose, arrangement and operation of the accessory, TB

2.2 Sketch of accessory

List of sources used

Introduction

Car repair is an objective necessity. The following economic and technical arguments lead us to this significance:

a) the need for the country's car fleet to be partially met by the operation of repaired cars;

b) during repair, those elements of cars that are not completely worn out (parts that have partially lost their operability) are used;

c) the restoration of parts contributes to metal saving (compared to the manufacture of new cars); at the same time, the metal consumption is 20... 30 times lower;

The need and expediency of repairing cars and units is due to the fact that parts, assemblies and units have an equally strong structure. Repair of the car, even by replacing some of its parts and units with a small service life, will always be expedient and economically justified. The state of the car achieved during operation, when all the profit from its transport work goes to maintain it in working condition, is called the limit - this is a sign of the need for overhaul at a car repair enterprise. The cost-effectiveness lies in the use of a residual service life (about 70% of the parts can be reused after a small repair or without repair). The restoration of parts achieves great savings in materials, energy, production and labor resources; Requirements for spare parts are met; provides the necessary number of the country's automobile fleet. For the optimal organization of repair of cars and units, restoration of parts, it is necessary to create a technical base that would provide for: introduction of progressive forms of labor organization, new methods, methods and technologies of repair, increased level of mechanization and automation of production, introduction of ACS, manipulators, robots, robotic complexes, flexible process lines, high-precision and productive equipment and technological equipment, development of non-impersonal CG with pre-repair and post-repair diagnostics, repair and restoration of foreign cars, implementation of centralized restoration of wide range of parts, reduction of labor costs, provision of high level of repair quality, reliability of repaired cars and units.

Analysis, calculations and practice show that the structure of the repair base of road transport should consist of three types of enterprises (according to the level of complexity of repair work): ATP workshops (minor maintenance repairs without disassembling units); without centralized most complex TR with disassembly of units and replacement of units; plants for CG of cars and units based on the non-impersonal method of CG.

When performing a course project, the student solves the following tasks:

1) consolidation of theoretical knowledge in the discipline;

2) acquisition of skills in the development of technological processes for the repair and assembly of cars and units, the design of simple structures of devices for them; Ability to calculate time standards for various part recovery operations

3) learn to use technical and reference literature, regulatory documents and GOST.

Process Part

1.1 Structural features and operating conditions of the part

The crankshaft pulley of the ZIL 431410 car is made of gray cast iron SCH 1532, GOST 141279.

The crankshaft pulley of the car ZIL 431410 No. 1301005050 accepts the following types of loads: increased load on the part, corrosion and the effect of aging of the material. The crankshaft pulley of the car ZIL 431410 No. 1301005050 is subject to natural aging and corrosion.

1.4 Causes of defects

The crankshaft pulley entering for repair has the following defects:

-Frames and cracks on sides edges

- Risks, balls or wear of neck under gland

- Wear of slot for key

- Wear of working surfaces of pulley grooves

During the operation of cars (with their parts and assemblies):

1. Aging - irreversible changes in the state and properties of the material;

2. Wear - separation of material from the surface of the part with changing its dimensions and shape (layer thickness, volume, mass);

3.Deformation - bending, twisting, warping, misalignment, non-perpendicular, distortion, dents;

4. Failures - violations of the integrity of the part due to the action of tangent, normal and tensile stresses during multiple overloads or its complete destruction%

5. Corrosion - destruction of the metal due to chemical or electrochemical effects of an aggressive medium;

Causes of wear and tear of parts are:

a) Abrasion - removal of metal particles from protrusions of micro irregularities during friction of parts;

b) Crumbling - plastic deformation and metal flow in the surface layer of conjugated parts, accompanied by changes in their dimensions;

c) Scratching - frictional surface destruction by particles having greater hardness than the part surface;

d) Fatigue cracks - cracks of parts in connection with the formation and further development of primary cracks in conditions of high, cyclic changing loads;

The cover of the side crankcase of the steering gear assembly during operation receives emergency damage.

Defect 2 - Debris and cracks on sides edges - occur as a result of improper pulley removal.

Defect 3 - Hairlines, bolts or wear of the neck under the gland - occurs as a result of lack of lubrication or incorrect fitting of the bushing.

Defect 5 - Wear of the slot under the key occurs due to careless adjustment of the key in place or application of incorrect fit.

Defect 6 - Working surfaces of pulley working grooves wear due to heavy belt tension.

Design Part

2.1 Purpose, arrangement and operation of the accessory.

Accessory is used for removal of pulley of ZIL431410 car crankshaft. It is very comfortable and practical in operation, small size. This puller can eliminate all difficulties in removing the crankshaft pulley.

The puller consists of the following main parts:

grabs;

braces;

nozzles;

traverses;

extractor screw;

tap;

12) tightening screws.

The principle of operation of this filmmaker is as follows:

remove the screw of brace (12) until the grip (1) becomes free;

turn wrench (6) to the left, remove screw (5) and install nozzle (3) on it;

install grips (1) of the extractor by the pulley of the crankshaft between partitions and, holding grip (1) with your hand, turn screw (12) of tie-rod (2) until stop so that grip (1) fits tightly to the crankshaft pulley;

screw of extractor (5), turning to the right of gate (6), rest against the end face;

when the screw of the extractor (5) rotates, the nozzle (3) will press into the end and create the opposite force back and under the action of this force the pulley will be removed.

Since the extractor screw, which is moved manually by cranking it, the force that needs to twist it, should not exceed the standard values ​ ​ (2-5 kg; ≈ 2050 N).