A method for manufacturing an aluminum alloy cylinder block of a rotary engine

Abstract

The application discloses a manufacturing method of an aluminum alloy cylinder body of a rotor engine and relates to the technical field of aluminum alloy cylinder body manufacturing of key parts of a rotor engine. The manufacturing method comprises the following steps: firstly, performing basic processing on a rotor engine aluminum alloy cylinder body casting blank, measuring the coordinates of selected points of the cylinder body and establishing a first coordinate data set; secondly, performing coating processing on the cylinder body, measuring the coordinates of selected points of the cylinder body after spraying and establishing a second coordinate data set; thirdly, calculating the coating thickness of corresponding coordinates by using the data in the first coordinate data set and the data in the second coordinate data set; fourthly, performing finishing processing on the cylinder body, measuring the coordinates of selected points of the cylinder body after finishing processing and establishing a third coordinate data set; and finally, calculating the coating thickness of finished products by using the data in the first coordinate data set and the data in the third coordinate data set. Through the technical scheme, the coating thickness of three functional areas of the engine cylinder body is adjusted, and the reliability and service life of the aluminum alloy cylinder body are increased.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of manufacturing aluminum alloy cylinder bodies of key components of a rotary engine, in particular to a manufacturing method of an aluminum alloy cylinder body of a rotary engine. BACKGROUND

[0002] The aluminum alloy cylinder body of a rotary engine is a cavity piece that is unevenly heated during operation. The cylinder body includes three functional areas: an intake area, a firing combustion area, and an exhaust area. These three functional areas are unevenly heated along the circumference during operation. The circular arc area on the intake side, commonly known as the cold arc area, is lower in temperature than the exhaust side, commonly known as the hot arc area, due to the cooling effect of fresh mixture. The temperature difference between these two areas is large, and this difference varies with the cylinder body material and operating speed. In this harsh operating condition, the firing combustion area generates extremely high temperatures due to the operation of the rotary engine, causing the aluminum alloy base material and coating in the aluminum alloy cylinder body to expand due to the difference in linear thermal expansion coefficients between the aluminum alloy base material and the coating, resulting in cracking of the aluminum alloy cylinder body, loss of coating, and reduced service life of the cylinder body.

[0003] To address the problem of coating failure of the aluminum alloy cylinder body of the rotary engine due to high temperatures in some areas and uneven heating in various areas during operation, most existing technologies currently solve the coating failure problem by changing the coating material and modifying the preparation process, thereby improving the use of the aluminum alloy cylinder body of the rotary engine. Therefore, there is an urgent need to design a manufacturing method and process flow for the aluminum alloy cylinder body of the rotary engine to solve the problem of optimal reliability and service life of the aluminum alloy cylinder body in the existing technology. SUMMARY

[0004] The purpose of the present application is to address the high temperature extreme condition by improving the cylinder body coordinate part in the key process of cylinder body processing, creating a cylinder body coordinate data set, monitoring the data and accurately calculating, and adjusting the coating thickness of the three functional areas of the engine cylinder body, thereby increasing the reliability and service life of the aluminum alloy cylinder body.

[0005] The technical solution of the present application is to provide a manufacturing method of an aluminum alloy cylinder body of a rotary engine, which comprises:

[0006] S1, manufacturing a rotary engine aluminum alloy cylinder body casting blank, processing a plane reference surface and a cylinder body double positioning hole;

[0007] S2, selecting points according to the angle and number of layers to be measured, measuring the corresponding coordinates of all selected points using a full-automatic optical image measuring instrument, and establishing a first coordinate data set using the coordinates of all points obtained by this measurement;

[0008] S3, coating processing is performed on the surface of the aluminum alloy cylinder body, so that the coating thickness is greater than the first processing thickness;

[0009] S4, after the coating processing is performed on the cylinder body, the coordinates of all selected points in S2 are measured for a second time, and a second coordinate data set is established using the coordinates of all points measured for the second time;

[0010] S5, using the data corresponding to the coordinates in the first coordinate data set and the data in the second coordinate data set, the coating thickness data of the corresponding coordinates is obtained;

[0011] S6, the cylinder body is subjected to wire cutting and finishing;

[0012] S7, after the cylinder body is subjected to wire cutting and finishing, the coordinates of all selected points in S2 are measured for a third time, and a third coordinate data set is established using the coordinates of all points measured for the third time;

[0013] S8, using the data corresponding to the coordinates in the first coordinate data set and the data in the third coordinate data set, the coating thickness data of the corresponding coordinates is obtained, and the cylinder body whose coating thickness meets the corresponding standard is regarded as a qualified product.

[0014] Further, in S1, a flat reference surface is first processed on the rotor engine aluminum alloy cylinder body casting, then the aluminum alloy cylinder body is positioned according to the flat reference surface, and the cylinder body double positioning hole is processed.

[0015] Further, the specific process of measuring the coordinates of the corresponding points in S2 is as follows:

[0016] The center of the flat reference surface of the cylinder body is taken as the coordinate origin, the flat reference surface of the cylinder body has a major axis and a minor axis, the major axis is taken as the X direction, the minor axis is taken as the Y direction, and the height direction of the cylinder body is taken as the Z direction to establish a coordinate system; the points to be measured are selected in turn, and the coordinates of each point are measured using a full-automatic optical image measuring instrument.

[0017] Further, the coating processing process of the aluminum alloy cylinder body is as follows:

[0018] The inner surface of the aluminum alloy cylinder body is subjected to sandblasting and texturing treatment, and is cleaned, high-temperature resistant thermal spraying adhesive tape is arranged on the hole position on the surface of the cylinder body and other areas except the spraying area, alloy powder is melted by using a spraying process, and is sprayed onto the inner surface of the aluminum alloy cylinder body.

[0019] Further, the selected angle and number of layers in S4 are the same as the selected angle and number of layers in S2; in S4, the coordinate measurement method used is the same as that in S2.

[0020] Further, the calculation formula in S5 is as follows:

[0021]

[0022] Wherein, B represents the second measurement, JN is the Nth angle, M is the layer number, N and M are positive integers, and B-JN-TM represents the first spraying coating thickness of the angle JN at the Mth layer position.

[0023] Further, the wire cutting and finishing processes of the aluminum alloy cylinder body are as follows:

[0024] The aluminum alloy cylinder body after coating processing in S3 is fixed on the machining equipment, the aluminum alloy cylinder body is fixed according to the plane reference surface of the aluminum alloy cylinder body, and the aluminum alloy cylinder body is circumferentially fixed according to the double positioning holes.

[0025] The aluminum alloy cylinder body is first wire cut, and then the aluminum alloy cylinder body is finished, so that the coating thickness is controlled within the range required by the product design.

[0026] Further, in S7, when measuring the coordinates of the selected points of the aluminum alloy cylinder body after finishing in S6, the selected angle and layer number are the same as those selected in S2; in S7, the coordinate measurement method used is the same as that in S2.

[0027] Further, the calculation formula in S8 is as follows:

[0028]

[0029] Wherein, C represents the third measurement, and C-JN-TM represents the coating thickness of the angle JN at the Mth layer after the completion of step S6.

[0030] The beneficial effects of the present application are:

[0031] Firstly, the present application designs a rotor engine aluminum alloy cylinder body coating coordinate data setting method to create a cylinder coordinate data set, realize the coordinate measurement of 70 points on the inner wall of the cylinder, monitor and control the coating thickness after the cylinder spraying process, and the coating thickness after the finishing process. The cylinder coating coordinate data set calculation method of the present application realizes the adjustment and control of the coating thickness of the three functional areas of the engine cylinder by monitoring and controlling the coating thickness after the cylinder spraying process and the coating thickness after the finishing process, so as to match the different functions and operating condition characteristics of the three functional areas of the rotor engine cylinder under different high temperature and high pressure working conditions, and achieve the best reliability and service life of the aluminum alloy cylinder body under the extreme working condition of the rotor engine.

[0032] Secondly, this invention designs a method for manufacturing an aluminum alloy cylinder block for a rotary engine, which can not only produce wear-resistant coatings for aluminum alloy cylinder blocks at a lower cost and higher efficiency, but also optimize and adjust the coating thickness in different areas of the cylinder block by combining the different functions of the three parts of the cylinder block and the different characteristics of high temperature and high pressure conditions. Attached Figure Description

[0033] Figure 1 This is a coordinate diagram of the aluminum alloy cylinder block coating of the rotary engine according to the present invention. Detailed Implementation

[0034] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that, unless otherwise specified, the embodiments of the present invention and the features thereof can be combined with each other.

[0035] In the following description, many specific details are set forth in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and therefore the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0036] like Figure 1 As shown, this embodiment provides a method for manufacturing an aluminum alloy cylinder block for a rotary engine, including:

[0037] S1. Fabricate the aluminum alloy cylinder block blank for the rotary engine, and machine the plane reference surface and the cylinder block double positioning holes.

[0038] The aluminum alloy ingots are melted and subjected to high-pressure die casting to form a rotary engine aluminum alloy cylinder block blank. The rotary engine aluminum alloy cylinder block blank is milled to form a plane reference surface. The side intake port, exhaust port and spark plug ignition port are machined on the rotary engine aluminum alloy cylinder block blank using drilling technology.

[0039] The planar reference surface of the aluminum alloy cylinder block casting blank of the rotary engine is used for planar positioning, and the cylinder block double positioning holes are machined; the planar base surface is the lower surface of the cylinder block.

[0040] S2. Select points according to the angle and number of layers to be measured, and use a fully automatic optical image measuring instrument to measure the corresponding coordinates of all selected points.

[0041] The center of the flat reference surface of the aluminum alloy cylinder body of the rotor engine is taken as the coordinate origin, the flat reference surface of the cylinder body has a long axis and a short axis, the long axis is taken as the X direction, the short axis is taken as the Y direction, and the height direction of the cylinder body is taken as the Z direction. 14 different angles are selected and named as J1 to J14, 5 different flat layers are selected, and a total of 70 points are selected, and the coordinate values of each point are measured in turn; in the first measurement, the coordinate values of each point are represented as (A-JN-XM, A-JN-YM, A-JN-ZM) in turn, and the coordinates of all the points are used to establish a first coordinate data set, wherein A represents the first measurement, JN represents the Nth angle, N is a positive integer less than or equal to 14, M represents the layer number, and M is a positive integer less than or equal to 5; for example, the coordinates of the angle J1 and the second layer are represented as (A-J1-X2, A-J1-Y2, A-J1-Z2), the coordinates of the angle J5 and the fifth layer are represented as (A-J5-X5, A-J5-Y5, A-J5-Z5), and the coordinates of the angle J14 and the first layer are represented as (A-J14-X1, A-J14-Y1, A-J14-Z1).

[0042] S3, spraying a layer on the surface of the aluminum alloy cylinder body of the rotor engine.

[0043] The inner surface of the aluminum alloy cylinder body is subjected to sand blasting and roughening treatment using white corundum, and the inner surface of the aluminum alloy cylinder body is cleaned using industrial alcohol, and a high-temperature-resistant thermal spraying adhesive tape is arranged on the surface and the hole of the cylinder body without thermal spraying.

[0044] The nickel-based alloy powder is melted by using a hot liquid oxygen and aviation kerosene supersonic thermal spraying process, and is sprayed onto the inner surface of the aluminum alloy cylinder body, so that the ion particle state of the molten and semi-molten alloy powder is embedded and combined on the cast aluminum alloy. The thickness of the nickel-based alloy powder coating on the surface of the aluminum alloy cylinder body after spraying is greater than 0.35 mm, there are no obvious cracks and defects, the porosity is about 1%, and the coating is firmly combined with the substrate.

[0045] S4, after the first spraying is completed, the 70 points of the cylinder body are subjected to a second coordinate measurement according to the standard of S2, and the coordinate values of each point are represented as (B-JN-XM, B-JN-YM, B-JN-ZM) in turn, wherein B represents the second measurement, and a second coordinate data set is established using the coordinates of all the points obtained by the second measurement.

[0046] S5, the coordinates obtained by the first measurement and the coordinates obtained by the second measurement of the corresponding points are substituted into the formula to calculate the coating thickness data of the corresponding coordinates of the first spraying, and the calculation formula is as follows:

[0047]

[0048] Wherein, B-JN-TM represents the first spraying coating thickness of angle JN at the Mth layer position.

[0049] S6, fixing the aluminum alloy cylinder after the spraying process on the machining equipment, and performing wire cutting and finishing machining on the cylinder;

[0050] fixing the aluminum alloy cylinder after the spraying process in S3 on the machining equipment, fixing the aluminum alloy cylinder according to the planar reference surface, and fixing the aluminum alloy cylinder according to the double positioning holes. First, performing wire cutting on the fixed aluminum alloy cylinder, and further machining the cylinder to meet the design requirements; then, using a precision coordinate grinding machine to perform finishing machining on the aluminum alloy cylinder, and uniformly controlling the nickel-based alloy spraying coating thickness within the range required by the product design, usually between 0.10-0.25, and using a polishing machine to perform mirror polishing on the inner surface of the aluminum alloy cylinder, and controlling the surface finish to within Rz0.10.

[0051] S7, after the completion of step S6, performing third coordinate measurement on the 70 points of the cylinder according to the standard of S2, and the coordinate values of each point are represented as (C-JN-XM, C-JN-YM, C-JN-ZM) in turn, wherein C represents the third measurement, and the coordinates of all points obtained by the third measurement are used to establish a third coordinate data set.

[0052] S8, substituting the coordinates obtained by the first measurement and the coordinates obtained by the third measurement of the corresponding points into the formula to obtain the coating thickness data of the corresponding coordinates after the completion of step S6, and the calculation formula is as follows:

[0053]

[0054] Wherein, C-JN-TM represents the coating thickness of angle JN at the Mth layer position after the completion of step S6.

[0055] When C-JN-TM meets the aluminum alloy cylinder surface coating thickness standard of the corresponding position, it is determined that the coating is qualified, otherwise it is unqualified.

[0056] The steps in the present application can be adjusted in sequence, combined and deleted according to actual needs.

[0057] The units in the device of the present application can be combined, divided and deleted according to actual needs.

[0058] Although the present application is disclosed in detail with reference to the drawings, it should be understood that the description is merely exemplary and is not intended to limit the application of the present application. The scope of protection of the present application is defined by the appended claims, and can include various modifications, improvements and equivalent solutions made to the application without departing from the scope and spirit of the present application.

Claims

1. A method for manufacturing an aluminum alloy cylinder block for a rotary engine, characterized in that, The manufacturing method of the aluminum alloy cylinder block of the rotary engine includes the following steps: S1. Manufacture the casting blank of the aluminum alloy cylinder block of the rotary engine, and process the plane reference surface and the double positioning holes of the cylinder block; S2. Establish a spatial coordinate system with the center of the plane reference surface as the coordinate origin. Select points according to the selected angles and layers to be measured, covering different functional areas inside the cylinder block. Use a fully automatic optical image measuring instrument to measure the corresponding coordinates of all selected points, and establish the first coordinate data set with the coordinates of all points obtained from this measurement; S3. Perform coating processing on the surface of the aluminum alloy cylinder block so that the coating thickness is greater than the first processing thickness; S4. After coating the cylinder block, perform a second measurement on the coordinates of all selected points in S2, and establish the second coordinate data set with the coordinates of all points obtained from the second measurement; S5. Use the data of the corresponding coordinates in the first coordinate data set and the data in the second coordinate data set for calculation to obtain the coating thickness data of the corresponding coordinates. The calculation formula is as follows: ； Among them, A represents the first measurement, B represents the second measurement, JN is the Nth angle, M is the number of layers, N and M are positive integers, and B - JN - TM represents the thickness of the first sprayed coating at the angle JN and at the position of the Mth layer; S6. Perform wire cutting processing and finish machining on the cylinder block, and control the coating thickness of different functional areas within the designed requirements; S7. After performing wire cutting processing and finish machining on the cylinder block, perform a third measurement on the coordinates of all selected points in S2, and establish the third coordinate data set with the coordinates of all points obtained from the third measurement; S8. Use the data of the corresponding coordinates in the first coordinate data set and the data in the third coordinate data set for calculation to obtain the coating thickness data of the corresponding coordinates. The cylinder block with the coating thickness meeting the corresponding standards is used as a qualified product. The calculation formula is as follows: ； Among them, C represents the third measurement, and C - JN - TM represents the coating thickness at the angle JN and at the position of the Mth layer after the processing in step S6; 2. The method for manufacturing the aluminum alloy cylinder block of the rotary engine as described in claim 1, characterized in that, In S1, first process the plane reference surface of the casting blank of the aluminum alloy cylinder block of the rotary engine, and then perform plane positioning on the aluminum alloy cylinder block according to the plane reference surface, and process the double positioning holes of the cylinder block; 3. The method for manufacturing the aluminum alloy cylinder block of the rotary engine as described in claim 1, characterized in that, The specific process of measuring the coordinates of the corresponding points in S2 is as follows: Take the center of the plane reference surface of the cylinder block as the coordinate origin. The plane reference surface of the cylinder block has a long axis and a short axis. Take the long axis as the X direction, the short axis as the Y direction, and the height direction of the cylinder block as the Z direction to establish a coordinate system; sequentially select the points to be measured, and use a fully automatic optical image measuring instrument to measure the coordinates of each point; 4. The method for manufacturing the aluminum alloy cylinder block of the rotary engine as described in claim 1, characterized in that, The coating processing process of the aluminum alloy cylinder block is as follows: Perform sandblasting and texturing treatment on the inner surface of the aluminum alloy cylinder block, and perform cleaning. Set high-temperature thermal spraying tapes at the hole positions on the surface of the cylinder block and other areas except the spraying area, and use the spraying process to melt the alloy powder and spray it onto the inner surface of the aluminum alloy cylinder block; 5. The method for manufacturing the aluminum alloy cylinder block of the rotary engine as described in claim 3, characterized in that, The selected angles and layers in S4 are the same as those selected in S2; in S4, the coordinate measurement method used is the same as the coordinate measurement method in S2; 6. The method for manufacturing the aluminum alloy cylinder block of the rotary engine as described in claim 1, characterized in that, [[ID= After the coating process is completed in S3, the aluminum alloy cylinder body is fixed on the processing equipment. The aluminum alloy cylinder body is fixed in plane according to the plane reference surface of the aluminum alloy cylinder body, and the aluminum alloy cylinder body is fixed in circumferentially according to the double positioning holes. First, the aluminum alloy cylinder body is machined using wire cutting, and then it is precision machined to control the coating thickness within the range required by the product design.

7. The method for manufacturing the aluminum alloy cylinder block of the rotary engine as described in claim 3, characterized in that, In S7, when measuring the coordinates of the selected points of the aluminum alloy cylinder block that have been finished in S6, the selected angle and number of layers are the same as those selected in S2; in S7, the coordinate measurement method used is the same as that used in S2.

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