Repair technology of the housing of bearings of the ZIL-130 car water pump

Contents

Introduction

1STRUCTURALLY - PROCESS ANALYSIS OF VEHICLE WATER PUMP BEARING HOUSING

1.1 Part designation and process analysis

1.2 Analysis of working conditions of the part in conjugation, types and processes of its wear and tear

1.3 Analysis of part defects and possible process recovery methods

1.4 Selection of process bases for processing

1.5 Development of part repair drawing

2 DEVELOPMENT OF PROCESS OF WATER PUMP COVER RESTORATION

2.1 Choosing a Rational Method of Recovery

2.2 Development of preliminary recovery route

2.3 Selection of process equipment, accessories, working tool, monitoring and measurement instruments

2.4 Development of part recovery roadmap

2.6 Developing Operating Cards

2.7 Development of part sketch maps

2.8 Process Feasibility Study

restoring a part

CONCLUSIONS

BIBLIOGRAPHIC LIST

Introduction

The efficiency of road transport is based on the reliability of rolling stock, which is ensured in the process of its production, operation and repair. During the operation of the car, its working properties are gradually deteriorated due to wear of the parts, as well as corrosion and fatigue of the material from which they are made. As a result, failures and malfunctions appear in the car. To maintain the rolling stock in serviceable, operable condition in motor transport enterprises (ATP), periodic maintenance (maintenance) and, if necessary, routine repair (TR) are carried out, which is carried out by replacing individual units, units and parts.

With long-term operation, cars reach a state where their repair in ATP conditions becomes technically impossible or economically impractical. In this case, they are sent for overhaul (CR) to a car repair enterprise (ARP).

The current repair must ensure the guaranteed operability of the car during mileage not less than the mileage to the next TO-2. overhaul must ensure serviceability and full or close to full (at least 80%) life of the car or unit by restoring and replacing any assembly units and parts, including basic ones.

The main source of cost-effectiveness of capital repairs is the use of the residual resource of their parts. About 7075% of car parts received for major repairs can be reused either without repair or after a slight repair impact (restoration of parts). As a result, a significant amount of past labor remains, materials are saved and production facilities for the manufacture of new cars are freed. Since the need and expediency of repairing cars is primarily due to the unequal strength of their components (assemblies and parts), i.e., parts wear out unevenly, have different service lives.

The number of parts whose working surfaces wear within the permissible limits reaches 3035%, which allows them to be used without repair. The remaining 4045% parts can only be reused once they have been recovered. These include, first of all, most of the most complex, metal-intensive and expensive parts of the car: cylinder block, crankshaft and camshaft, cylinder head, rear axle transmission crankcases, etc. The cost of restoring these parts does not exceed 1050% of the cost of their manufacture, and the consumption of materials is 2030 times lower. Therefore, one of the main issues of car repair production is the restoration of worn out parts.

Part recovery is a major reserve for automotive spare parts, which currently cost 4060% of the cost. Expanding the range of the part to be restored reduces the need for automotive repair in spare parts.

Improving the reliability of repaired cars and units is the main task facing ARP, which depends largely on the quality in the restoration of parts. Currently, the car repair industry has modern methods of restoring parts that provide after repair resources for parts at the level of new and higher. In some cases, restoring parts is the only possibility of restoring the operability of any product and not only the car.

To restore the serviceability of the units and assemblies, restoration of the initial fit of the interface is necessary, most often this is carried out by increasing the worn-out surfaces in one way or another, namely by surfacing, applying electrolytic or synthetic coatings and then treating them to a nominal size.

In some cases, the initial fit is restored by changing the initial dimensions of the mating parts (method of repair dimensions), setting an additional repair part (bushing, convolution, etc.), as well as methods based on the movement of the metal of the part to its worn part.

Restoration of a part of a limited nomenclature can be organized on ATP if there is appropriate equipment. Recovery volumes at ATP are determined by the availability of spare parts corresponding to the name and price used in car repair.

The purpose of this course project is to develop a process for restoring the part, housing of the ZIL130 water pump. At the same time, the following tasks are solved in the project:

- Selecting an effective method for restoring a part

- determination of the part process recovery route;

- selection of installation bases, equipment, working and measuring tools, process equipment;

- selection of cutting and processing modes;

- determination of technical norm of time for part restoration;

- determination of qualification of workers by specialties;

- drawing up of route routing;

- determination of cost price and cost efficiency of part restoration;

Conclusions

As a result of the course work, the following tasks were solved:

- analysis of water pump housing design was performed;

- You have chosen how to restore the part.

- repair documentation for part restoration has been developed;

- part repair process is developed;

- technical and economic indicators of the project are calculated.