Restoration of axis of centrifugal oil purification filter rotor - heading

Contents

CONTENTS:

Introduction

1 General part

1.1 Characteristics of the part

1.2 Part Defect Specification

1.3 Defects of the part and their causes

1.4 Technical Requirements for Repaired Part

2 Process Part

2.1 Selection of rational method of part restoration

2.2 Selection of process bases

2.3 Process diagrams of defects elimination

2.4 Calculation of allowances

2.5 Part Recovery Process Route

2.6 Calculation of processing modes

2.7 Calculation of time standards

2.8 Development of roadmap, sketch map, two operational maps

2.9 Safety requirements, fire prevention and environmental protection

2.10 Waste disposal and recycling, Spanish secondary resources

3 Structural part

3.1 Analysis of existing fixture structures

3.2 Purpose and arrangement of the accessory

3.3 Operation principle of the accessory

3.4 Calculation of the accessory for strength

Conclusion

List of sources used

Appendix A

Appendix B

Introduction

The relevance of exploring ways to restore machine parts is quite great in the modern world. This is due to the fact that most repair enterprises are developing their own programs to reduce production costs for the maintenance and repair of their fleet of machines. The development of such programs not only reduces the cost of servicing and repairing equipment, but also improves the quality of the repair or restoration of units and mechanisms.

Not every organization can, when their equipment fails, simply buy a new one. To do this, their management structure creates entire departments in which you design the most cost-effective ways to restore parts. These departments allow the enterprise to restore the operability of its equipment much faster, thereby reducing the need to purchase new parts, units and mechanisms.

The purpose of this course design is to develop the technological process of restoring the axis of the rotor of the centrifugal oil purification filter of the YaMZ236 engine using the lowest costs.

Development of roadmap, sketch map, two operating maps

Development of roadmap, two operating cards is given in Appendix B

Safety requirements, fire prevention and environmental protection

Safety requirements.

Accidents at work most often occur as a result of neglect of safety regulations by both individual enterprise managers and workers.

The main role in the fight against injuries is played by ensuring safe working conditions (when organizing sites, installing equipment, etc.) and along with them - promoting safety, instructing and training in safe working methods.

If road machines are repaired in the premises, it is necessary to divert special welding and surfacing areas provided for by the process. Welding (surfacing) of small and medium parts at stationary stations is carried out in open-type cabins. The area occupied by one post should be not less than 4 m2, the width of the passages between the posts - not less than 1 m. To protect workers not related to surfacing work, from the radiation of an electric arc, the posts should be protected with stable fire-resistant screens or shields, the dimensions of which are determined by the dimensions of the parts being repaired.

The rooms should be well lit. Illumination in the working plane (from general lighting lamps) in welding areas (surfacing) shall be at least 50 lx with incandescent lamps and 150 lx with luminescent lamps. The walls of the rooms and welding cabins must be painted in light tones (gray, blue) to reduce the sharp contrast between the brightness of the arc and the dark surfaces of the walls.

To protect the breathing organs of the welder from the harmful effects of gases and dust fractions, a plenum ventilation system (local or general) is installed in the room. For gas protection during surfacing in carbon dioxide, the air velocity created by local suction must be not more than 0.5 m/s, and in argon medium - not more than 0.25 m/s. Production rooms shall have a temperature of not less than 16 ° С. Lifting and transportation mechanisms shall be installed in areas where parts weighing more than 20 kg are welded.

At the end of operation or at temporary interruptions in operation, the welding plant must be turned off.

The electric welder must work in dry, whole and clean work clothes, shoes and gloves (sleeves).

Occupational Safety Regulations

Basic Rules for Occupational Safety and Safety when Working on Machines. Work on the machine is allowed in overalls, headgear and protective glasses. The jacket (robe) must be fastened to all buttons, the sleeves must fit tightly to the hands. Operation on a faulty machine is strictly prohibited. If workpieces weighing more than 20 kg are processed on the machine, it is allowed to install them and remove them from the machine only with the help of lifting mechanisms in compliance with all safety measures.

Only persons who have passed the appropriate instruction are allowed to work on the machines.

Workpieces and cutting tools must be firmly and securely secured.

Chips shall be cleaned with special hooks or brushes.

It is forbidden to work without a protective screen, leave the key in the cartridge, brake the cartridge with your hand, process long shafts without a lunette.

When machining on drilling machines, the parts must be firmly clamped in the clutches, directly on the table or in the conductor. Holding the part with your hands is not allowed.

Environmental protection activities.

Nature protection refers to a set of measures for the rational use, reproduction and protection of natural resources, and the prevention of pollution and destruction of the natural environment.

Environmental quality control services play an important role in the protection of the environment in order to conduct systematic observations of the state of the atmosphere, water and soil in order to obtain actual levels of environmental pollution. The obtained information on pollution makes it possible to quickly identify the causes of increased concentrations of harmful substances in the environment and actively eliminate them.

Waste management and recycling, use of secondary resources

In order to ensure the cleanliness of production, modern methods of cleaning and recycling materials are used, many of which are processed and reused, for example:

1) To prevent contamination of soils and rivers with sewage, their treatment and further use are provided;

2) Parts and units unsuitable for repair and further operation, as well as faulty equipment and tools are stored in a specially designated place. As they accumulate, they are handed over to the point of receiving scrap of non-ferrous and ferrous metals, and then go to remelting;

Secondary resources - raw materials, materials, products and production wastes which are formed at production and can be applied further in production at production of new products. The use of secondary resources is generally economically preferable to the extraction, enrichment and preparation of primary resources.

Design Part

3.1 Analysis of existing fixture structures

When repairing car engines, there is often a need to dismantle the cylinder liner from the engine block, for its replacement or repair. The operation to remove the liner from the block is often very time consuming, since the coupling of the liner-block of the cylinder during engine operation is subject to high temperatures and corrosion.

In practice, in conditions of repair shops that are not equipped with the necessary devices and technological equipment for repair work, the locksmith and motorist most often knocks the sleeve out of the block from the side of the pallet using hammer strikes on the lower belt of the sleeve through a mandrel of low rigidity (wooden or brass)

It is not surprising that such a method of dismantling sometimes ends with damage to the sleeve in the form of a chipping or a fragment of its lower belt and an expensive part must be rejected

People's craftsmen from among mechanics of motorists use during this operation a simple device consisting of a threaded pair of screw-nut with thrust or square thread and two plates, one of which is made in the form of a bracket, and the second can be flat

The screw freely passes through the central hole in the bracket and plate and is screwed into the nut by tightening the plates together. The bracket and plate serve as stops during removal operation. At that, the bracket rests from the side of the upper belt of the liner against the engine block and the plate from below rests against the sleeve skirt and extrudes it from the cylinder block when the screw is screwed into the nut.

The use of such a device allows you to benefit economically by increasing the productivity of repair work and in terms of improving the culture of repair production. Reduced costs for recovery and purchase of parts damaged by improper removal methods

In addition, it is not necessary to use various percussion tools, often used in the above compounds with low efficiency, which can lead not only to damage to the part, but also to industrial injuries.

3.3 Operation principle of the accessory

The principle of operation of the accessory consists in the following engine piston is supplied to the upper part of the sleeve at the same time between its bottom and the upper plane of the unit there must be a gap for installation of arched clamps

Holding the clamps with their hands until contact with the surface of the sleeve, the nut is rotated, at the same time the bolts are turned out of it and the arched clamps are firmly wedged in the upper belt of the sleeve. After that, by rotating the crankshaft, the piston is lifted into the seat and it pushes the sleeve out of the seat together with the accessory. As a rule, on the upper belt of the working surface of the sleeve, ring is formed which prevents the displacement of the arched clamps when the sleeve is released

Conclusion

In this course design, I developed the technological process of restoring the axis of the rotor of the centrifugal oil purification filter of the YaMZ236 engine using the lowest costs, namely:

1) sketches of the part to be repaired are made;

2) the technological bases of attachment of the part in the three-cap cartridge for each type of its processing are correctly selected;

3) all possible methods of restoring this part have been studied and the most cost-effective is selected;

4) operational sketches, roadmaps, as well as operational maps with a working drawing have been developed.

From the data obtained above, it can be said that in order to understand how the process of restoring the part goes, it is necessary not only the knowledge and skills gained in the process of studying technical documentation and literature, but also the use of practical skills obtained in production .