Equipment and method for manufacturing engine front cover prototype

Abstract

This invention belongs to the field of engine research and development prototype technology, specifically relating to a manufacturing equipment and method for an engine front cover prototype. The manufacturing equipment includes a tooling base plate with at least one set of positioning holes. These positioning holes match the clamping bolt holes on the engine front cover prototype to be processed. A positioning support structure is replaceably provided within the positioning hole set. This positioning support structure is used to provide matching support for the engine front cover prototype during rough and fine machining. The purpose is to achieve the rough machining and finishing processes of the engine front cover prototype using only one tooling base plate and two sets of replaceable bolts, which is convenient and fast, resulting in high tooling utilization during single-piece and small-batch production; and significantly reducing prototype manufacturing costs.

Description

Technical Field

[0001] This invention belongs to the field of engine research and development and trial production technology, specifically relating to a manufacturing equipment and method for an engine front cover prototype. Background Technology

[0002] In the development of new engines, a small number of prototypes need to be made for testing. Traditional metal prototype manufacturing involves three main stages: mold making, casting, and machining. Mold making and casting of the blank prototypes are time-consuming and expensive. Once the mold is made, changes to the product design are difficult, further increasing the manufacturing cycle and cost. The machining stage requires multiple sets of specialized machining fixtures for the blank prototypes, and design changes also necessitate changes to these fixtures. Therefore, the method of mold making, casting, and then machining is only suitable for large-scale prototype production or mass production of finished products, and not for single-piece or small-scale prototype production in the early stages of development. Using 3D printing of blanks followed by machining is one solution in the early stages of development, but currently, metal 3D printing is relatively expensive, which is not conducive to cost control. Currently, for small-scale prototype prototyping, a shorter-cycle and lower-cost sample processing solution is often used, which involves processing all processes from aluminum ingots to finished prototypes, eliminating the mold making and blank casting stages.

[0003] Chinese patent CN113404616A discloses a front cover and its processing method, which requires the design of three tooling fixtures for positioning and clamping. These tooling fixtures are typically complex steel fixtures, with workpiece fixation often employing one-sided two-pin positioning, clamping with a pressure plate or other threaded mechanisms. The clamping elements occupy space on the workpiece, affecting processing and requiring additional steps for pre-designed processes to accommodate this space, thus increasing processing steps. Furthermore, new product prototypes are mostly produced in single-piece or small-batch production; the long manufacturing cycle of steel tooling results in low tooling utilization for single-piece or small-batch production, increasing trial production costs. Summary of the Invention

[0004] The purpose of this invention is to provide an equipment and method for manufacturing engine front cover prototypes, in order to solve the problems that most new product trial prototypes are produced in single or small batches, the steel tooling manufacturing cycle is long, the tooling utilization rate is low and the trial production cost is high when producing single or small batches.

[0005] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows:

[0006] An engine front cover sample manufacturing equipment includes a tooling base plate, wherein at least one set of positioning holes is provided on the tooling base plate, the positioning hole set matches with a plurality of clamping bolt holes on the engine front cover sample to be processed, and a positioning support structure is replaceably provided in the positioning hole set, the positioning support structure being used to match and support the engine front cover sample during rough machining and finish machining.

[0007] Preferably, the positioning support structure includes a first bolt and a second bolt, the first bolt being matched to the rough machining process of the engine front cover sample, and a first leveling block being fitted on the first bolt;

[0008] The second bolt is matched with the precision machining process of the engine front cover sample, and a second level block is fitted on the second bolt.

[0009] Preferably, the tooling base plate has a mounting groove for matching with the machine tool.

[0010] A method for manufacturing an engine front cover sample, applied to the aforementioned engine front cover sample manufacturing equipment, the method comprising:

[0011] S1: Multiple first bolts pass through the positioning hole group from side A of the tooling base plate. The first equal height block is sleeved on the first bolt. The aluminum ingot with multiple clamping bolt holes is installed on the tooling base plate through the first bolt. The outer contour surface and the first machining end face of the engine front cover sample are rough machined.

[0012] S2: Multiple first bolts pass through the positioning hole group from side B of the tooling base plate, the first equal height block is sleeved on the first bolts, and the aluminum ingot is installed on the tooling base plate through the first bolts to perform rough machining on the second machining end face of the engine front cover sample.

[0013] S3: Multiple second bolts pass through the positioning hole group from side A of the tooling base plate, the second level block is fitted on the second bolts, and the aluminum ingot is installed on the tooling base plate through the first bolt to perform precision machining on the engine front cover sample.

[0014] Further specifying, the rough machining of the outer contour surface and the first machining end face of the engine front cover sample includes:

[0015] S1.1: Machining the cavity outline of the front cover, with a 0.5mm allowance reserved on the mounting surface of the front cover, and machining the front and rear end faces of the cavity outline to the dimensions required by the drawing;

[0016] S1.2: Roughly machine the oil seal hole on the first machining end face, with a machining allowance of 0.2mm for the oil seal hole;

[0017] S1.3: Roughly machine the bottom hole of the Ф6 mounting pin hole on the first machining end face, with a machining allowance of 0.2mm reserved for the bottom hole of the mounting pin hole;

[0018] S1.4: Machining a first M6 threaded hole on the first machining end face.

[0019] Further specifying, the rough machining of the second machining end face of the engine front cover sample includes:

[0020] S2.1: External contour of the cover before processing;

[0021] S2.2: Machining a second M6 threaded hole on the oil seal hole mounting surface;

[0022] S2.3: Machining four Ф11 bolt through holes on the second machining end face;

[0023] S2.4: Roughly machine the sensor mounting hole on the second machining end face, and then perform fine machining.

[0024] Further specifying, the finishing process of the engine front cover sample includes:

[0025] S3.1: Complete the finishing of the front cover mounting surface, with a flatness accuracy requirement of 0.05mm;

[0026] S3.2: Complete the finishing of the oil seal hole, with a hole diameter accuracy requirement of 0-0.05mm;

[0027] S3.3: Complete the precision machining of the Ф6 mounting pin hole, with a hole diameter accuracy requirement of 0~0.012mm.

[0028] Further specifying, the method also includes: removing the engine front cover sample from the tooling base plate and enlarging the mounting bolt holes.

[0029] The invention employing the above technical solution has the following advantages:

[0030] 1. In this solution, only one tooling base plate is needed. By changing two sets of bolts, the rough machining process of fixing the engine front cover sample can be realized. It is convenient and quick. The tooling utilization rate is high when producing single pieces in small batches, which greatly reduces the trial production cost.

[0031] 2. In this solution, at least one set of positioning holes is provided on the tooling base plate. The positioning hole set is used in conjunction with the positioning support structure to support and fix the engine front cover sample for processing. The positioning hole set can be one set or multiple independent sets to adapt to different engine front cover samples for processing. Alternatively, a new positioning hole set can be formed by only opening positioning holes corresponding to the different clamping bolt holes on the original engine front cover sample, so that one tooling base plate can be matched to the processing of multiple engine front cover samples. Attached Figure Description

[0032] The present invention can be further illustrated by the non-limiting embodiments given in the accompanying drawings;

[0033] Figure 1 This is a schematic diagram of the A-side of the tooling base plate of an embodiment of an engine front cover sample manufacturing equipment according to the present invention;

[0034] Figure 2 This is a schematic diagram of the B-side of the tooling base plate in an embodiment of an engine front cover sample manufacturing equipment according to the present invention;

[0035] Figure 3 This is a flowchart illustrating the steps of a method for manufacturing an engine front cover sample according to the present invention.

[0036] Figure 4 This is a schematic diagram of an aluminum ingot being mounted on surface A of a tooling base plate for processing in a method for manufacturing an engine front cover sample according to the present invention.

[0037] Figure 5 This is a schematic diagram showing the first intermediate processing part being mounted on surface B of the tooling base plate for processing in a method for manufacturing an engine front cover sample according to the present invention.

[0038] Figure 6 This is a schematic diagram showing the second intermediate processing part being mounted on surface A of the tooling base plate for processing in a method for manufacturing an engine front cover sample according to the present invention.

[0039] Figure 7 This is a flowchart illustrating the steps involved in manufacturing a prototype of an engine front cover according to the present invention to obtain the product.

[0040] Figure 8 This is a schematic diagram of the structure of an engine front cover sample manufactured by the engine front cover sample manufacturing method of the present invention.

[0041] The symbols for the main components are explained below:

[0042] 1. Tooling base plate; 11. Mounting slot; 2. Positioning hole group; 3. Engine front cover sample; 31. Clamping bolt hole; 4. First bolt; 41. First leveling block; 5. Second bolt; 51. Second leveling block. Detailed Implementation

[0043] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that similar or identical parts are referred to by the same reference numerals in the drawings or description. Implementations not shown or described in the drawings are forms known to those skilled in the art. In addition, directional terms mentioned in the embodiments, such as "up," "down," "top," "bottom," "left," "right," "front," and "back," are only for reference to the directions in the drawings and are not intended to limit the scope of protection of the present invention.

[0044] like Figures 1 to 8 As shown, an engine front cover sample manufacturing equipment of the present invention includes a tooling base plate 1. Mounting grooves 11 matching the mounting structure on a machine tool are provided on both sides of the tooling base plate 1. The upper and lower sides of the tooling base plate 1 are respectively designated as surface A and surface B. At least one set of positioning holes 2 penetrating from surface A to surface B of the tooling base plate 1 is provided on the tooling base plate 1. Positioning support structures are interchangeably provided inside the positioning hole set 2.

[0045] like Figure 1 and Figure 2 As shown, in this embodiment, the preferred number of positioning hole groups 2 is one group, with 6 positioning holes. It is understood that in other embodiments of this application, the number of positioning hole groups 2 can also be set to multiple independent groups. Alternatively, when producing various different engine front cover sample parts 3, it is not necessary to process multiple independent positioning hole groups 2; only the positioning holes corresponding to the different clamping bolt holes 31 on the new engine front cover sample part 3 and the original engine front cover sample part 3 need to be processed, resulting in low cost and strong versatility.

[0046] like Figures 4 to 6 As shown, in this embodiment, the positioning support structure includes a first bolt 4 and a second bolt 5. The first bolt 4 is equipped with a first leveling block 41, and the second bolt 5 is equipped with a second leveling block 51. During the rough machining process, multiple first bolts 4 pass through the positioning hole group 2, and the first leveling block 41 is fitted onto the first bolts 4. The engine front cover sample 3 to be machined is fixedly mounted on the tooling base plate 1 by the first bolts 4. The tooling base plate 1 is then mounted on the machine tool through the mounting groove 11 for rough machining.

[0047] During the finishing process, multiple second bolts 5 pass through the positioning hole group 2, and the second level block 51 is fitted onto the second bolts 5. The rough-machined engine front cover sample 3 is fixedly installed on the tooling base plate 1 by the second bolts 5. The tooling base plate 1 is installed on the machine tool for finishing through the mounting groove 11.

[0048] like Figures 3 to 7As shown, this application also provides a method for manufacturing an engine front cover sample, applied to the aforementioned engine front cover sample manufacturing equipment, the method comprising:

[0049] S1: Multiple first bolts 4 pass through the positioning hole group 2 from the A side of the tooling base plate 1. The first equal height block 41 is fitted on the first bolts 4. The aluminum ingot with multiple clamping bolt holes 31 is installed on the tooling base plate 1 through the first bolts 4. The outer contour surface and the first machining end face of the engine front cover sample 3 are rough machined.

[0050] S2: Multiple first bolts 4 pass through the positioning hole group 2 from the B side of the tooling base plate 1, the first equal height block 41 is sleeved on the first bolts 4, and the aluminum ingot is installed on the tooling base plate 1 through the first bolts 4 to perform rough machining on the second machining end face of the engine front cover sample 3.

[0051] S3: Multiple second bolts 5 pass through the positioning hole group 2 from the A side of the tooling base plate 1, the second leveling block 51 is fitted on the second bolts 5, and the aluminum ingot is installed on the tooling base plate 1 through the first bolt 4 to perform precision machining on the engine front cover sample 3.

[0052] In this embodiment, surface A of the tooling base plate 1 faces the aluminum ingot with clamping bolt holes 31. The first bolt 4 passes through the positioning hole group 2, and the first end face of the aluminum ingot is installed on the tooling base plate 1 with the first end face facing upward. The tooling base plate 1 is then installed on a lathe, and the outer contour surface and the first machining end face are rough machined to obtain the first intermediate machined part.

[0053] During the machining process, the machining zero point is detected and set by the machine tool probe. Different detection points can be selected for different processes. The machining coordinates are unified through coordinate transformation, eliminating the need to set a zero point positioning device on the tooling, thus simplifying tooling manufacturing.

[0054] After the first end face is rough machined, the fixture base plate 1 is flipped so that the B side faces the flipped first intermediate machined part. The first intermediate machined part with the second machining end face facing up is installed onto the fixture base plate 1 by the first bolt 4. The fixture base plate 1 is then installed onto the lathe for rough machining of the second machining end face to obtain the second intermediate machined part.

[0055] Then, surface A of the tooling base plate 1 faces the second intermediate workpiece, the first machining end face of the second intermediate workpiece faces upward, the second bolt 5 passes through the positioning hole group 2, and the second intermediate workpiece is installed on the tooling base plate 1 for precision machining.

[0056] like Figure 4 As shown, in this embodiment, the outer contour surface and the first machining end face of the engine front cover sample 3 are rough-machined to obtain the first intermediate machined part, including the following steps:

[0057] S1.1: Machining the cavity outline of the front cover, with a 0.5mm allowance reserved on the mounting surface of the front cover, and machining the front and rear end faces of the cavity outline to the dimensions required by the drawing;

[0058] S1.2: Roughly machine the oil seal hole on the first machining end face, with a machining allowance of 0.2mm for the oil seal hole;

[0059] S1.3: Roughly machine the bottom hole of the Ф6 mounting pin hole on the first machining end face, with a machining allowance of 0.2mm reserved for the bottom hole of the mounting pin hole;

[0060] S1.4: Machining a first M6 threaded hole on the first machining end face.

[0061] like Figure 5 As shown, in this embodiment, the second machining end face of the engine front cover sample 3 is rough-machined to obtain a second intermediate machined part, including the following steps:

[0062] S2.1: External contour of the cover before processing;

[0063] S2.2: Machining a second M6 threaded hole on the oil seal hole mounting surface;

[0064] S2.3: Machining four Ф11 bolt through holes on the second machining end face;

[0065] S2.4: Roughly machine the sensor mounting hole on the second machining end face, and then perform fine machining.

[0066] like Figure 6 As shown, in this embodiment, the engine front cover sample 3 is precision machined, including the following steps:

[0067] S3.1: Complete the finishing of the front cover mounting surface, with a flatness accuracy requirement of 0.05mm;

[0068] S3.2: Complete the finishing of the oil seal hole, with a hole diameter accuracy requirement of 0-0.05mm;

[0069] S3.3: Complete the precision machining of the Ф6 mounting pin hole, with a hole diameter accuracy requirement of 0~0.012mm.

[0070] Understandably, the clamping bolt holes 31 on the aluminum ingot are for easy fixing via the positioning hole group 2 during machining. The number of mounting holes on the engine front cover sample 3 may be more than the number of clamping bolt holes 31. Therefore, during the machining of the first intermediate machining part, clamping bolt holes 31 corresponding to the number of mounting holes can also be machined on the first machining end face. In addition, the clamping bolt holes 31 on the aluminum ingot can be through holes, which facilitates flipping the ingot to machine the second machining end face after the first machining end face is completed, or they can be closed hole structures, where clamping bolt holes 31 are machined again during rough machining of the first machining end face to facilitate the fixing of the first intermediate machining part.

[0071] Furthermore, the method also includes: removing the precision-machined engine front cover sample 3 from the tooling base plate 1, and enlarging the mounting bolt holes 31.

[0072] In this solution, only one tooling base plate 1 is needed. By replacing two sets of bolts, the rough machining of the engine front cover sample 3 can be achieved. This is convenient and quick, and the tooling has a high utilization rate in single-piece and small-batch production, which greatly reduces the trial production cost.

[0073] The foregoing has provided a detailed description of the equipment and method for manufacturing an engine front cover sample according to the present invention. The specific embodiments described are merely for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make various improvements and modifications to the present invention without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A method for manufacturing a prototype of an engine front cover, characterized in that: Applications in engine front cover prototype manufacturing equipment; The equipment includes a tooling base plate (1), on which at least one set of positioning holes (2) are provided. The positioning holes (2) match multiple clamping bolt holes (31) on the engine front cover sample (3) to be processed. A positioning support structure is replaceably provided in the positioning hole set (2). The positioning support structure is used to match and support the engine front cover sample (3) during rough and fine machining. The positioning support structure includes a first bolt (4) and a second bolt (5). The first bolt (4) matches the rough machining process of the engine front cover sample (3). A first equal-height block (41) is fitted on the first bolt (4). The second bolt (5) is matched with the precision machining process of the engine front cover sample (3), and a second equal height block (51) is fitted on the second bolt (5); The upper and lower sides of the tooling base plate (1) are respectively set as surface A and surface B; The method includes: S1: Multiple first bolts (4) pass through the positioning hole group (2) from the A side of the tooling base plate (1), the first equal height block (41) is sleeved on the first bolts (4), and the aluminum ingot with multiple clamping bolt holes (31) is installed on the tooling base plate (1) through the first bolts (4) to perform rough machining on the outer contour surface and the first machining end face of the engine front cover sample (3); S2: Multiple first bolts (4) pass through the positioning hole group (2) from the B side of the tooling base plate (1), the first equal height block (41) is sleeved on the first bolts (4), the aluminum ingot is installed on the tooling base plate (1) through the first bolts (4), and the second machining end face of the engine front cover sample (3) is rough machined. S3: Multiple second bolts (5) pass through the positioning hole group (2) from the A side of the tooling base plate (1), the second level block (51) is fitted on the second bolts (5), the aluminum ingot is installed on the tooling base plate (1) through the second bolts (5), and the engine front cover sample (3) is precision machined.

2. The method for manufacturing an engine front cover sample according to claim 1, characterized in that: The tooling base plate (1) is provided with a mounting slot (11) for matching with the machine tool.

3. The method for manufacturing an engine front cover sample according to claim 1, characterized in that: The rough machining of the outer contour surface and the first machining end face of the engine front cover sample (3) includes: S1.1: Machining the cavity outline of the front cover, with a 0.5mm allowance reserved on the mounting surface of the front cover, and machining the front and rear end faces of the cavity outline to the dimensions required by the drawing; S1.2: Roughly machine the oil seal hole on the first machining end face, with a machining allowance of 0.2mm for the oil seal hole; S1.3: Roughly machine the bottom hole of the Ф6 mounting pin hole on the first machining end face, with a machining allowance of 0.2mm reserved for the bottom hole of the mounting pin hole; S1.4: Machining a first M6 threaded hole on the first machining end face.

4. The method for manufacturing an engine front cover sample according to claim 1, characterized in that: The rough machining of the second machining end face of the engine front cover sample (3) includes: S2.1: External contour of the cover before processing; S2.2: Machining a second M6 threaded hole on the oil seal hole mounting surface; S2.3: Machining four Ф11 bolt through holes on the second machining end face; S2.4: Roughly machine the sensor mounting hole on the second machining end face, and then perform fine machining.

5. A method for manufacturing an engine front cover sample according to claim 3, characterized in that: The finishing process of the engine front cover sample (3) includes: S3.1: Complete the finishing of the front cover mounting surface, with a flatness accuracy requirement of 0.05mm; S3.2: Complete the finishing of the oil seal hole, with a hole diameter accuracy requirement of 0~0.05mm; S3.3: Complete the precision machining of the Ф6 mounting pin hole, with a hole diameter accuracy requirement of 0~0.012mm.

6. The method for manufacturing an engine front cover sample according to claim 1, characterized in that: The method further includes: removing the engine front cover sample (3) from the tooling base plate (1) and enlarging the mounting bolt hole (31).

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