Supercharger gas inlet shell machining method and clamp

Abstract

The invention discloses a supercharger fuel gas inlet shell machining method and a clamp. The production cycle and the product quality of a fuel gas inlet shell are guaranteed. The method includes scribing; a small-end inclined plane is machined with the allowance reserved; the end faces, the outer circle face and the inner hole of the large end are firstly machined on a vertical boring and milling center, then a large-end flange hole and two positioning pin holes in a large-end flange are machined, and finally other structures on the large end face and threaded holes in a semispherical arc structure are machined; milling convex outer planes of the reinforcing ribs, drilling through holes in the reinforcing ribs, drilling and tapping outer end threads of the through holes, boring inner planes of the reinforcing ribs, and drilling and tapping inner end threads of the through holes in the reinforcing ribs; boring the outer circle of the small-end-face flange; a small end boss plane of the small end side face is machined, and then a threaded through hole in a small end boss is drilled and tapped; sealing and water pumping are conducted on the fuel gas inlet shell; machining parts of small ends of the parts; and step 90, clamping.

Description

Technical Field

[0001] The present invention relates to the technical field of marine turbocharger superchargers, and particularly to a processing method and fixture for a gas inlet housing of a supercharger. Background Art

[0002] As an important component of the supercharger housing, the gas inlet housing is an important channel for guiding exhaust gas into the supercharger, and its quality directly affects the performance and service life of the supercharger. The gas inlet housing is connected and assembled with relevant components through a flange, and the relative positional relationship of the flange holes and the quality of the holes must be effectively guaranteed to prevent assembly interference.

[0003] The outer shape of the gas inlet housing is in a bent tube shape, and the center lines of the two end face flanges intersect at 45°. The large end flange face is bolt-connected, and the small end flange face is clamp-connected. The two flange center lines have a relative positional relationship to ensure accurate and reliable assembly positions.

[0004] The gas inlet housing can be processed by a five-axis machining center, a numerical control boring machine, or an ordinary boring machine, and all three processing methods have disadvantages and difficulties.

[0005] a) Five-axis machining centers are mostly used for processing precision parts. The production in the factory is busy and cannot meet the required cycle of customers. Moreover, the processing cost of parts and the labor cost of five-axis machining centers are relatively high, which is also a test for operators and programming technicians.

[0006] b) Numerical control boring machines and ordinary boring machines cannot directly machine the 45° flange face and need to rotate the workbench angle in a horizontal placement manner for machining. Since the gas inlet housing has an irregular shape, the clamping force is insufficient when machining the 45° small end flange face and the clamp slope in a horizontal placement manner, resulting in a vibration phenomenon and the product quality cannot be guaranteed.

[0007] C) The inclined holes in the internal cavity of the gas inlet housing can only be machined in a horizontal placement manner on a numerical control or ordinary boring machine, and a boring and milling tooling can be used to achieve the machining of the inclined holes. Summary of the Invention

[0008] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a processing method and fixture for a gas inlet housing of a supercharger, which ensures the production cycle and product quality of the gas inlet housing.

[0009] The purpose of the present invention is achieved as follows:

[0010] A processing method for the gas inlet housing of a supercharger. The gas inlet housing has a housing body, a large-end flange, and a small-end flange. The housing body is a conical tube bent at 45°, and the inside of the housing body is a conical flow channel. The large-end flange and the small-end flange are respectively located at the large end and the lower end of the housing body. The axis lines of the large-end flange and the small-end flange form a 45° angle. A hemispherical arc structure is provided at the center of the large end face of the housing body, and the hemispherical arc structure is connected to the inner wall of the flow channel of the housing body through a reinforcing rib. There is a through hole in the middle of the reinforcing rib, and threaded holes are provided at both ends. A small-end boss is provided outside the small end of the housing body corresponding to the reinforcing rib, and a threaded through hole is provided on the small-end boss. This method includes the following processes:

[0011] Process 10: Marking

[0012] Level the back of the large-end flange, and take the starting dimension after leveling as the reference to mark the respective processing lines of the large end; align the starting dimension and mark the respective processing lines of the small end according to the height dimension;

[0013] Process 20: Boring

[0014] An adjustable support is used for the large end face. The back of the flange of the large-end flange is pressed tightly by a pressing plate. Align the corresponding marked lines of the large end, and leave a 1-mm allowance to machine the small-end inclined plane on a vertical boring and milling center;

[0015] Process 30: Boring

[0016] Place the small-end inclined plane horizontally on the workbench, press the back of the small-end flange tightly by a pressing plate, first machine the respective end faces, outer circular surfaces, and inner holes of the large end on a vertical boring and milling center, then machine the flange holes of the large-end flange and the two positioning pin holes on the large-end flange, and finally machine the other structures on the large end face and the threaded holes on the hemispherical arc structure;

[0017] Process 40: Boring

[0018] Rotate the workbench of the vertical boring and milling center, align the center of the large-end flange, mill the outer plane of the convex part of the reinforcing rib, drill the through hole on the reinforcing rib, and drill and tap the thread at the outer end of the hole;

[0019] Process 50: Boring

[0020] Install the milling tooling. Based on the two positioning pin holes machined in Process 30, position the part through the large end and clamp it and fix it on the milling tooling. Rotate the workbench of the horizontal boring machine, determine the center position of the through hole on the reinforcing rib through the milling tooling, align the through hole on the reinforcing rib, bore the inner plane of the reinforcing rib, drill and tap the thread at the inner end of the through hole on the reinforcing rib; rotate the workbench again, make the small-end flange perpendicular to the machine spindle, determine the center of the small-end flange through the milling tooling, and bore the outer circle of the small-end flange;

[0021] Process 60: Boring

[0022] The small end face is placed horizontally on the workbench and pressed by a pressing plate. Machine the plane of the small end boss on the side of the small end, and then drill and tap the threaded through hole on the small end boss.

[0023] Process 70: Pump water

[0024] Pump water to seal the gas inlet housing for checking the sealing performance.

[0025] Process 80: Turning

[0026] Install the turning tooling. Position the part through the large end and clamp it on the turning tooling. The small end flange face is in a horizontal state. There is a measuring surface on the turning tooling. After aligning the outer circle of the small end flange, use the lathe to measure the distance between the plane of the small end flange and the measuring surface of the turning tooling, and machine each part of the small end of the part according to the height dimension.

[0027] Process 90: Fitter work

[0028] Preferably, in Process 10, level the back of the large end flange. Taking the starting dimension as the reference, mark the machining lines of each end face of the large end respectively; considering each external structure of the large end, draw a cross center line on the large end face and extend it to the outer contour surface and the back of the large end flange; considering each internal structure of the large end, draw a calibration circle line; align the starting dimension, and draw a cross center line on the inclined surface of the small end according to the height dimension and extend it to the outer contour and the back of the small end flange.

[0029] Preferably, when the part is clamped and fixed on the milling tooling, the through hole on the reinforcing rib is in the horizontal direction. Use the milling tooling to convert the inclined hole into a straight hole in the horizontal direction for easy machining.

[0030] Preferably, the milling tooling is provided with a tool setting surface and a positioning hole. The tool setting dimension of the tool setting surface is used to determine the center position of the through hole on the reinforcing rib, and the positioning hole is used to determine the center position of the small end flange.

[0031] Preferably, in Process 70, after pumping water, clean the inner cavity of the housing, air dry it and brush it with oil for rust prevention.

[0032] A turning tooling fixture used in a processing method for a supercharger gas inlet housing includes a welded base and a positioning pin. The welded base includes a positioning plate, a support plate, a base and a counterweight. The support plate and the base are perpendicularly welded to each other. The measuring surface of the turning tooling is the upper end surface of the support plate. The positioning plate is welded to the base and the support plate at a 45° angle. The positioning plate is provided with a positioning pin hole and a threaded connection hole. The counterweight is fixedly connected to the base and is arranged facing away from the support plate. Connect the gas inlet housing through the positioning plate. The positioning pin hole is used for pin connection and positioning, and the threaded connection hole is used for bolt fixation. Control the center line dimension and tolerance of the two flange faces of the gas inlet housing through the detection dimension between the measuring surface of the turning tooling and the small end face of the gas inlet housing.

[0033] Preferably, in process 90, the part is positioned by its small end and clamped on the positioning plate. The large end face of the part is in a horizontal state, and a counterbore is milled for the flange hole at the large end of the part.

[0034] Due to the adoption of the above technical solution, the present invention has the following beneficial effects:

[0035] (1) By using the boring and milling center to leave a margin and first machining the rough datum, that is, the 45° flange face at the small end, the positioning face of the large end flange and the flange connection pin holes are machined using the rough datum. The part is connected to the tooling with bolts and positioning pins for subsequent boring of inclined holes and positioning and clamping during turning of the small end face, solving the problem of difficult positioning and clamping due to the special structure of the part.

[0036] (2) By using the milling tooling to convert the inclined hole into a straight hole in the horizontal direction, the center of the inclined hole can be determined on the horizontal boring machine through the tool setting dimensions on the milling tooling. The internal cavity inclined hole and the threaded hole are machined. At the same time, the outer diameter of the small end flange is bored with a margin according to the tool setting dimensions on the milling tooling, leaving an alignment position for subsequent turning of the small end flange face, solving the difficulty of machining the inclined hole on the horizontal boring machine and reducing the processing cost.

[0037] (3) By using the turning tooling to convert the 45° small end flange face into a horizontal state, the center position relationship between the two end flanges is converted from an unmeasurable space dimension to the height dimension from the end face to the measuring surface of the tooling. The clamping force is insufficient and the horizontal boring machine cannot machine the inclined surface due to the part structure.

[0038] (4) By combining the small end face turning tooling with the existing turning tooling pressing plate, the connection holes on the large end flange are in a vertical state, solving the problem that the ordinary drill press cannot counterbore the inclined hole.

[0039] (5) All processing equipment is the existing equipment in the factory, and the production cycle of other parts is not affected during the processing, greatly shortening the manufacturing cycle of the product, winning the affirmation of customers, and ensuring the market share.

[0040] (6) It breaks the inherent processing idea of the gas inlet housing of the turbocharger, that is, the processing method combining boring and milling, provides another processing method, adopts turning processing, and accumulates valuable experience for the processing of such parts in the future. Description of the Drawings

[0041] Figure 1 For the processing of the gas inlet housing Figure One ;

[0042] Figure 2 For the processing of the gas inlet housing Figure Two ;

[0043] Figure 3 It is the process drawing for 10 processes;

[0044] Figure 4 It is the process drawing for 20 processes;

[0045] Figure 5 It is the process drawing for 30 processes;

[0046] Figure 6 It is the process drawing for 40 processes;

[0047] Figure 7 It is the process drawing for 50 processes;

[0048] Figure 8 It is the process drawing for 80 processes;

[0049] Figure 9 It is the general assembly drawing of the tooling for machining the gas inlet housing;

[0050] Figure 10 It is the welding base drawing of the tooling for machining the gas inlet housing;

[0051] Figure 11 It is the locating dowel drawing of the tooling for machining the gas inlet housing;

[0052] Figure 12 It is the general assembly drawing of the milling tooling;

[0053] Figure 13 It is the schematic diagram of the clamping and locating symbols. Detailed implementation manners

[0054] The overall gas inlet housing is in a bent tube shape, the center lines of the flanges at both ends intersect at 45°, and the overall flow path and outer shape from the large-end flange to the 45° small-end flange show a taper trend. The internal main body is a conical flow path structure, and there is a hemispherical arc structure on the large end face, which is connected to the inner wall of the flow path through a reinforcing rib. There are inclined holes with a middle through hole and threads at both ends on the reinforcing rib.

[0055] Due to the special structure of the part, in combination with the existing processing equipment and production situation of the company, the present invention uses a vertical and horizontal boring and milling center to machine the rough reference surface and flange holes, a horizontal boring machine to machine the inclined holes on the reinforcing rib and the remaining holes of the part, and a CNC vertical lathe to machine the 45° small-end flange surface and the inclined degree of the reverse side of the flange, and designs corresponding milling tooling and turning tooling to machine the part.

[0056] The existing processing methods for the remaining gas inlet housings in the company are all boring and milling. The biggest difference between the present invention and the traditional process is that the present invention introduces CNC lathe equipment for the processing of the gas inlet housing. The new processing route not only does not conflict with the existing production tasks, but also ensures the production cycle and product quality of the gas inlet housing. By using different types of equipment for processing, the present invention successfully solves the problems of difficult positioning and clamping, high processing cost, and unsuitable processing methods for the gas inlet housing.

[0057] The specific content is as follows:

[0058] The blank of the gas inlet housing of the turbocharger has a housing, a first flange (i.e., the large-end face flange), and a second flange (i.e., the 45° flange of the small end face). The housing is a conical tube bent at 45°. The first flange and the second flange are located at the two ends of the housing. The axis lines of the first flange and the second flange intersect at 45°. This method includes the following processes:

[0059] Process 10: Marking

[0060] Level the back of the large-end flange, mark the machining line of the large end face according to the starting dimension of 25 ± 0.5, and then mark the machining lines of the end faces of 4.5 ± 0.04 and 4.9 ± 0.05; taking into account the petal flange and the convex platform on the back of the housing, draw a cross center line on the large end face and extend it to the outer contour surface and the back of the large-end flange; borrow the blank drawing, taking into account the large-end inner hole φ457 and the outer circle φ304 of the internal cavity, and draw the calibration circle line; taking into account the convex surface of the housing (the small-end convex platform), align the starting dimension marking of 25, and draw the cross center line on the inclined surface of the small end according to the height dimension of 416.2 ± 0.2 and extend it to the outer contour and the back of the small-end flange.

[0061] Process 20: Boring

[0062] For the large end face, use an adjustable support, press and clamp the back of the first flange with a pressure plate, align the starting dimension marking of 25 mm in Process 10 and the marking on the back of the large-end flange, and leave a 1-mm allowance to machine the 45° inclined surface on the TRT314 vertical boring and milling center.

[0063] Process 30: Boring

[0064] Place the machined 45° inclined surface horizontally on the workbench, press and clamp the back of the small-end flange with a pressure plate, first machine the starting dimension of 25 ± 0.5 on the TRT314 vertical boring and milling center, and then successively machine the outer circle dimension of φ481.3 ± 0.5, the inner hole dimension of φ465.3 ± 0.1, the end face dimensions of 4.5 ± 0.04 and 4.9 ± 0.05, and the remaining chamfers and fillet dimensions. Then machine the 22 - φ18 holes and the 2 - φ18 (+0.018,0) positioning pin holes (for subsequent fixture positioning) on the large-end flange, and finally machine the 3 U-shaped grooves and the M33×2 threaded holes on the large end face.

[0065] Process 40: Boring

[0066] Rotate the workbench of the TRT314 vertical boring and milling center, align the center of the large-end flange, mill the outer plane of the reinforcing rib to the dimension of 255, drill the through holes on the reinforcing rib, and drill and tap the threads at the outer end of the through holes.

[0067] Process 50: Boring

[0068] Upper milling tooling. The inclined hole is converted into a straight hole in the horizontal direction by using the milling tooling. After positioning the part and the milling tooling with two positioning pins, they are connected by bolts. Rotate the table of the T68 horizontal boring machine to 25°. Determine the center position of φ25 through the tool setting dimensions 164.1, 416.2 and 365 on the milling tooling, align the machined φ25 through hole, bore the inner plane of the stiffener to the dimension of 130, drill and tap the M33×2 thread at the inner end of the φ25 through hole; Rotate the table again to make the small end face flange perpendicular to the machine tool spindle, and determine the center of the small end face flange through the φ14 positioning hole and the height dimension 365 on the milling tooling, and bore the outer circle of the small end face flange to the dimension of φ402. Specific steps:

[0069] 1). For the upper milling tooling, after positioning the part and the milling tooling with the two symmetric pin holes machined in the previous process 30, use bolts to tighten to clamp the part horizontally.

[0070] 2). The milling tooling converts the center dimensions 164.1 and 416.2 of the two planes on the drawing to the bottom plate of the milling tooling through the positioning plate, specifically shown as the distances from the two notches to the intersecting plane;

[0071] 3). The center of the φ14 hole on the milling tooling is at the intersection position of 164.1 and 416.2, and is coplanar in the direction perpendicular to the small end plane of the part; The center positions of the two end faces are controlled to be on the same horizontal line through the height dimension 365.

[0072] 4). Adjust the milling tooling to make one of its straight edges (not the 45° straight edge) parallel to the table. After aligning the center of the φ14 hole on the milling tooling, offset it upward by 365 to determine the center position of the hole on the Z-direction stiffener. Determine the center position of the hole on the X-direction stiffener by offsetting 416.2 through the two notches on the milling tooling, and offset 164.1 to determine the center position of the hole on the Y-direction stiffener, thereby determining the center position of the hole on the stiffener.

[0073] 5). Align the machined φ25 through hole, bore the inner plane of the stiffener to the dimension of 130, drill and tap the M33×2 thread at the inner end of the φ25 through hole;

[0074] 6). Keep the height dimension 365 in the Z direction unchanged, rotate the table 25°, make the small end face flange perpendicular to the machine tool spindle, and bore the outer circle of the small end face flange to the dimension of φ402.

[0075] Process 60: Boring

[0076] Place the small end face horizontally on the table, clamp it with a pressing plate, machine the plane of the convex platform on the side of the small end to the dimension of 173, and drill and tap the 2-M18×1.5 threaded through holes on the convex platform according to the dimensions of 106 (leaving 1 mm allowance from the center to the small end face) and 146 (leaving 1 mm allowance from the center to the small end face).

[0077] Process 70: Pumping water

[0078] Seal the pump water for the gas inlet housing to check the airtightness of the inlet housing, then clean the inner cavity of the housing, dry it and apply oil for rust prevention.

[0079] Process 80: Turning

[0080] Install the turning tooling. After positioning the part and the turning tooling through two locating pin holes, connect them with bolts to make the small end flange face horizontal. After aligning the machined outer circle of the small end flange in Process 50, use a lathe to measure the distance between the small end flange plane and the measuring surface of the turning tooling. Machine the small end flange and the 20° slope, the outer circle φ400 and other dimensions according to the height dimension of 155.7 ± 0.3.

[0081] Process 90: Fitter

[0082] Use the existing positioning plate of the turning tooling in Process 80 to make the large end face of the part horizontal. Use a Z35 to counterbore the reverse side of the 24 - φ18 through holes on the φ512 center circle to φ32 with a depth of 2 mm; chamfer the sharp edges of the part, deburr it, and clean it; laser engrave the part according to the drawing requirements.

[0083] The present invention includes a turning tooling for a gas inlet housing of a turbocharger, which comprises two parts, namely a welded base and a positioning pin. The welded base consists of a positioning plate, a support plate, a base and a counterweight. The support plate and the base are perpendicularly welded to each other. The positioning plate has positioning pin holes and threaded connection holes, and is welded to the base and the support plate at an angle of 45°. The counterweight is thread - connected to the base. After the base, the support plate and the positioning plate are welded, they are machined as a whole to ensure the positioning dimensions and inspection dimensions required by the tooling drawing. The present invention is realized as follows: connect the gas inlet housing and the turning tooling through the positioning plate. The pin holes play a positioning role, and the threaded holes play a connection role, making the small end face of the gas inlet housing horizontal for subsequent CNC vertical lathe machining. By the inspection dimensions between the support plate and the small end face of the gas inlet housing, control the center line dimensions and tolerances of the two flange faces of the gas inlet housing.

[0084] Finally, it should be noted that the above - mentioned preferred embodiments are only used to illustrate the technical solutions of the present invention rather than to limit them. Although the present invention has been described in detail through the above - mentioned preferred embodiments, those skilled in the art should understand that various changes can be made in form and details without departing from the scope defined by the claims of the present invention.

Claims

1. A method for processing a turbocharger gas inlet shell, characterized in that: The gas inlet shell has a shell, a large end flange and a small end flange. The shell is in a 45° bent conical tube shape. The interior of the shell is a conical flow channel. The large end flange and the small end flange are located at the large end and the lower end of the shell respectively. The axis lines of the large end flange and the small end flange are at an angle of 45°. A hemispherical arc structure is provided at the center of the large end surface of the shell. The hemispherical arc structure is connected to the inner wall of the flow channel of the shell through a reinforcing rib. There is a through hole with a middle penetration and threads at both ends on the reinforcing rib. A small end boss is provided on the outside of the small end of the shell corresponding to the reinforcing rib, and a threaded through hole is provided on the small end boss. The method comprises the following steps: Step 10: Marking Level the back of the large end flange, and use the starting dimension of the leveling as the reference to mark out the processing lines of the large end; align the starting dimension, and mark out the processing lines of the small end according to the height dimension; Process 20: Boring The large end face adopts adjustable support, the back of the large end flange is pressed by a pressure plate, the corresponding marking line of the large end is aligned, and the small end bevel is machined on the vertical boring and milling center with a margin; Process 30: Boring The small end inclined surface is placed horizontally on the workbench, and the back of the small end flange is pressed by a pressure plate. The end faces, outer cylindrical surface, and inner hole of the large end are first processed on the vertical boring and milling center, and then the large end flange hole and the two positioning pin holes on the large end flange are processed. Finally, other structures on the large end surface and the threaded holes on the hemispherical arc structure are processed; Process 40: Boring Rotate the vertical boring and milling center table, find the center of the large end flange, mill the raised outer plane of the reinforcement rib, drill the through hole on the reinforcement rib, and drill and tap the outer end thread of the hole. Process 50: Boring The upper milling tooling, based on the two positioning pin holes processed in process 30, positions the part through the large end, and clamps and fixes it on the milling tooling, boring the inner plane of the reinforcement rib, drilling and tapping the inner end thread of the through hole on the reinforcement rib; boring the outer circle of the small end face flange; Process 60: Boring The small end face is placed horizontally on the workbench, and a pressure plate is placed to press it tightly. The small end boss plane on the side of the small end is processed, and then the threaded through hole on the small end boss is drilled and tapped; Process 70: Pumping water Pump water into the gas inlet casing seal to check the tightness; Process 80: Car Put the part on the lathe, position it through the big end, and clamp it on the lathe. The small end flange surface is in a horizontal state. The lathe is equipped with a measuring surface. After aligning the outer circle of the small end flange, the lathe uses a table to measure the distance between the small end flange plane and the measuring surface of the lathe. Process the parts of the small end according to the height size. Process 90: Pliers.

2. A method for processing a supercharger gas intake shell according to claim 1, characterized in that: In process 10, the back of the big end flange is leveled, and the end surface processing lines of the big end are marked based on the starting size; taking into account the external structures of the big end, a cross center line is drawn on the big end surface, and led to the outer contour surface of the big end and the back of the big end flange; taking into account the internal structures of the big end, a calibration circle line is drawn; the starting size is aligned, and according to the height size, a cross center line is drawn on the inclined surface of the small end and led to the outer contour of the small end and the back of the small end flange.

3. A method for machining a supercharger gas intake casing according to claim 1, characterized in that: When the parts are clamped and fixed on the milling fixture, the through holes on the reinforcing ribs are in the horizontal direction.

4. A method for machining a supercharger gas intake casing according to claim 1, characterized in that: In step 70, after the water is pumped out, the inner cavity of the shell is cleaned, and after air drying, oil is applied to prevent rust.

5. A lathe fixture used in the method for machining a supercharger gas intake housing according to claim 1, characterized in that: It includes a welding base and a positioning pin. The welding base includes a positioning plate, a support plate, a base and a counterweight. The support plate and the base are welded vertically to each other. The measuring surface of the lathe is the upper end surface of the support plate. The positioning plate is welded to the base and the support plate at 45 degrees. The positioning plate is provided with a positioning pin hole and a threaded connection hole. The counterweight is fixedly connected to the base and is arranged with its back to the support plate. The gas intake shell is connected to the positioning plate through the positioning plate. The positioning pin hole is used for pin connection positioning, and the threaded connection hole is used for bolt fixing. The center line size and tolerance of the two flange surfaces of the gas intake shell are controlled by detecting the size between the measuring surface of the lathe and the small end surface of the gas intake shell.

6. A method for machining a supercharger gas intake casing according to claim 5, characterized in that: In process 90, the part is positioned by the small end and clamped on the positioning plate, the large end surface of the part is in a horizontal state, and the flange hole at the large end of the part is countersunk.

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