进气歧管的工艺研究与应用
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摘要
近年来,我国汽车工业的发展迅速,在全世界汽车领域中占据着越来越重要的地位。汽车及其零部件的开发及制造能力也在不断提高。我公司从98年开始与日本三菱汽车公司合作,一直生产4G6系列发动机,目前正在试制的4G69发动机采用的是可变气门技术,性能比正在生产的4G63、4G64有一定的优势,但还有待于进一步提高。
发动机整体性能的提高,每一个部件都至关重要。因此对进气系统的重要部件进气歧管也提出了更高的性能要求和成品率要求,使其在发动机工作过程中起到降低进气阻力,提高充气量的作用,达到提高发动机性能的目的;同时提高进气歧管的制造质量,达到降低成本的目的。
本文重点介绍了4G69发动机进气歧管的试制过程,对影响进气歧管内表面影响因素进行了分析,对采用的芯砂平均细度AFS、激冷效果、工艺参数等进行了试验研究,并对不同的试验件进行了发动机性能测试,取得了比较满意的结果。
With the rapid development of automobile industry, new products and new technology come forth continuously. Engine as the“heart”part of motor vehicle, its properties directly influence the complete vehicle. SAME company produces 4G6 series engines up to now, among them, the new type of 4G69 engine adopts VVT technology, it has much more advantages in properties than that of 4G63 and 4G64 type of engine. Every part and component is crucial to the improvement of overall properties of engine. So it has high demands on properties and percentage of pass of intake manifold– important part of air intake system, to reduce the resistance of intake manifold to the inlet air during operation of engine, to enhance the amount of inlet air, to meet the demands of enhancing engine properties; And also to enhance the manufacturing quality of intake manifold, to reach the goal of reducing the cost.
Metal mold and resin coated sand core making are adopted in intake manifold production, the inner surface of intake manifold is rather rough. The structure of 4G69 intake manifold is complicated, and process technology is difficult, especially, it has much higher demands on the roughness of inner surface. How to enhance the inner surface quality of intake manifold in production process, to reduce the harmful effect on the properties of engine; To enhance the percentage of pass, to reduce the cost of production, are the new task we face.
This article analyzed the factors that influence the inner surface of intake manifold, experimentally studied the average grain fineness of core sand ASF, chilling effect, process parameters, and tested the engine properties with different test pieces, during trial manufacturing of intake manifold,the main work is as follows:
1) Theoretically analyzed the influence of inner surface quality to the engine properties, the inner surface quality of intake manifold influences the inlet air factor, and directly influences the power, torque, and gas consumption rate of engine.
2) Analyzed process technology of intake manifold, to determine casting methods; gravity casting, hot core box resin coated sand core making were adopted. To ensure manufacturability, and higher percentage of pass, pouring temperature, mold temperature, mold structure and alloy were adjusted.
3) To reach the demand of inner surface roughness of casting, and to improve permeability, experimental studied average grain fineness of core sand and concentration ratio of tree sieves.
4) Analyzed metal solidification theory, to strengthen chilling ability, and to enhance feeding capacity. We studied the chill resin coated sand. Experimented on different ratio of chromite sand, chill additive to reduce the porosity defect, and to enhance the inner surface quality,
5) Coating the resin coated sand core with graphite coating, analyzed and verified its influence on inner surface roughness and chilling effect on casting.
6) Tested engine properties with two different intake manifolds of normal resin coated sand and chill resin coated sand
Tested low speed torque value, maximum torque value, maximum output power value and gas consumption rate.
Experiment results indicate:
1) Found out the value of core sand average grain fineness AFS by experiment, when AFS value is greater than 55, the inner surface roughness can reach 6.3. Production of intake manifold with resin coated sand of average grain fineness of 65- 75.
2) Experiment of distribution of permeability and grain size. When three sieve concentration is greater than 90%, and main sieve percentage is greater than 35%, the permeability of core is good. But in production verification, there is porosity in inner surface of casting, and the roughness of inner surface is not uniform.
3) Experiment of normal resin coated sand, with **% chromite sand, and with **% chill additive RC-5. When in heating condition, enthalpy change, measure the heat absorption, to find out the chilling ability. With the increase of chromite sand, the chill effect stably enhanced, but hot strength drop greatly. Conclusions with different proportion: the result with **% RC-5 is good, and the hot strength, normal temperature strength is also good, gas evolution value is reasonable. The verification by production, porosity defect drops obviously.
4) Graphite coating has chilling effect to some degree, and can decrease the inner surface roughness value, because of the complicated operation, the factors of human are too many, it is proved that the chilling effect is not obvious, and there is not much effect to the percentage of pass of castings.
5) Test of engine properties, the result s are as follows: The torque and power of engine with intake manifold using normal resin coated sand core can’t reach the demand of sample engine. The torque, power and gas consumption rate of engine with intake manifold using chill resin coated sand can reach the properties of original sample engine. And also satisfy technical specifications.
By comparation, test of engine with intake manifold using chill resin coated sand technology; the power of engine can be heightened by 4.66%.
发动机整体性能的提高,每一个部件都至关重要。因此对进气系统的重要部件进气歧管也提出了更高的性能要求和成品率要求,使其在发动机工作过程中起到降低进气阻力,提高充气量的作用,达到提高发动机性能的目的;同时提高进气歧管的制造质量,达到降低成本的目的。
本文重点介绍了4G69发动机进气歧管的试制过程,对影响进气歧管内表面影响因素进行了分析,对采用的芯砂平均细度AFS、激冷效果、工艺参数等进行了试验研究,并对不同的试验件进行了发动机性能测试,取得了比较满意的结果。
With the rapid development of automobile industry, new products and new technology come forth continuously. Engine as the“heart”part of motor vehicle, its properties directly influence the complete vehicle. SAME company produces 4G6 series engines up to now, among them, the new type of 4G69 engine adopts VVT technology, it has much more advantages in properties than that of 4G63 and 4G64 type of engine. Every part and component is crucial to the improvement of overall properties of engine. So it has high demands on properties and percentage of pass of intake manifold– important part of air intake system, to reduce the resistance of intake manifold to the inlet air during operation of engine, to enhance the amount of inlet air, to meet the demands of enhancing engine properties; And also to enhance the manufacturing quality of intake manifold, to reach the goal of reducing the cost.
Metal mold and resin coated sand core making are adopted in intake manifold production, the inner surface of intake manifold is rather rough. The structure of 4G69 intake manifold is complicated, and process technology is difficult, especially, it has much higher demands on the roughness of inner surface. How to enhance the inner surface quality of intake manifold in production process, to reduce the harmful effect on the properties of engine; To enhance the percentage of pass, to reduce the cost of production, are the new task we face.
This article analyzed the factors that influence the inner surface of intake manifold, experimentally studied the average grain fineness of core sand ASF, chilling effect, process parameters, and tested the engine properties with different test pieces, during trial manufacturing of intake manifold,the main work is as follows:
1) Theoretically analyzed the influence of inner surface quality to the engine properties, the inner surface quality of intake manifold influences the inlet air factor, and directly influences the power, torque, and gas consumption rate of engine.
2) Analyzed process technology of intake manifold, to determine casting methods; gravity casting, hot core box resin coated sand core making were adopted. To ensure manufacturability, and higher percentage of pass, pouring temperature, mold temperature, mold structure and alloy were adjusted.
3) To reach the demand of inner surface roughness of casting, and to improve permeability, experimental studied average grain fineness of core sand and concentration ratio of tree sieves.
4) Analyzed metal solidification theory, to strengthen chilling ability, and to enhance feeding capacity. We studied the chill resin coated sand. Experimented on different ratio of chromite sand, chill additive to reduce the porosity defect, and to enhance the inner surface quality,
5) Coating the resin coated sand core with graphite coating, analyzed and verified its influence on inner surface roughness and chilling effect on casting.
6) Tested engine properties with two different intake manifolds of normal resin coated sand and chill resin coated sand
Tested low speed torque value, maximum torque value, maximum output power value and gas consumption rate.
Experiment results indicate:
1) Found out the value of core sand average grain fineness AFS by experiment, when AFS value is greater than 55, the inner surface roughness can reach 6.3. Production of intake manifold with resin coated sand of average grain fineness of 65- 75.
2) Experiment of distribution of permeability and grain size. When three sieve concentration is greater than 90%, and main sieve percentage is greater than 35%, the permeability of core is good. But in production verification, there is porosity in inner surface of casting, and the roughness of inner surface is not uniform.
3) Experiment of normal resin coated sand, with **% chromite sand, and with **% chill additive RC-5. When in heating condition, enthalpy change, measure the heat absorption, to find out the chilling ability. With the increase of chromite sand, the chill effect stably enhanced, but hot strength drop greatly. Conclusions with different proportion: the result with **% RC-5 is good, and the hot strength, normal temperature strength is also good, gas evolution value is reasonable. The verification by production, porosity defect drops obviously.
4) Graphite coating has chilling effect to some degree, and can decrease the inner surface roughness value, because of the complicated operation, the factors of human are too many, it is proved that the chilling effect is not obvious, and there is not much effect to the percentage of pass of castings.
5) Test of engine properties, the result s are as follows: The torque and power of engine with intake manifold using normal resin coated sand core can’t reach the demand of sample engine. The torque, power and gas consumption rate of engine with intake manifold using chill resin coated sand can reach the properties of original sample engine. And also satisfy technical specifications.
By comparation, test of engine with intake manifold using chill resin coated sand technology; the power of engine can be heightened by 4.66%.
引文
[1] 国家信息经济咨询中心编,全国乘用车市场十年滚动预测报告.2003
[2] 赵英,中国汽车工业发展趋势及对策,2006
[3] Chen Yong, Chen Quanshi, Sun Fengchun. Motion Analysis of an Electric Vehicle with Two Independent Drive Motors, JOURNAL OF BEIJING INSTITUTE OF TECHNOLOGY, 2004.13.1: P109-112
[4] Zhao Xuhong. How far can China's motors driver in the international market?. CHINA'S FOREIGN TRADE, 2003.9: P16-17
[5] 腾逸风,发动机新技术及发展趋势,2006
[6] Heinz Heisler.Advanced Engine Technology.London Edward Amold.1995.
[7] S.A.Niemi,J.A.Pit Kanen and J.B.Tamminen.Development of Different Neat Ethanol Driven Direct-Injection Truck and Tractor Engines.X ISAF vol.I,478~491.Colorado 1993.
[8] H.Hong,T.Krepec and R.M.H.Cheng.Optimization of Electronically Controlled Injectors for Direct Injection of Natural Gas in Diesel Engines.
[9] Michael Walsh.Globle Treds in Diesel Particutlate Control –A 1995 Update.SAE 950149.
[10] Kiyoshi Hatono,Kazumasa Lida,Hirohumi Higashi and Shinichi Murata.Development of New Multi-Mode Variable Valve Timing Engine.
[11] Naoto Miyoshi,Naoki Takahashi,Kouichi Kasahara and et al.Development of New Concept Three Catalyst for Automotive Lean –Burn Engines.SAE 950809.
[12] B.Pfalzgraf,E.Otto.A Wirth,and et al .The System Development of Electrically Heated Catalyst(EHC) for The LEV and EU Ⅲ Legislation. Audi AG,bmw ag,1995.
[13] Martin J.Heimrich,Lawrence R .Smith,and Jack Kitowski.Cold-startHydrocarbon Collection for Advanced Exhaust Emission control.SAE920847.
[14] 陈培陵,汽车发动机原理.北京,人民交通出版社,2004
[15] 浅析发动机进气系统,中华建筑机械网,2006
[16] 汽车工程手册 设计篇 .人民交通出版社.2001
[17] 贺礼清, 工程流体力学.石油工业出版社. 2004
[18] 周龙保、刘巽俊、高宗英,内燃机学. 机械工业出版社,1999 年 5 月,第 1 版,(215)
[19] 于洪水,发动机与汽车原理.北京大学出版社.2005
[20] 高延龄,汽车应用工程.北京,人民交通出版社,1999
[21] 倪计民等,电喷汽油机可变进气系统的优化设计
[22] 范守宏,试论我国汽车有色铸件的发展,中国铸造装备与技术 5/2006
[23] 李玉青,吴殿杰,铸件轻量以及铝镁铸件的应用.4/2005 中国铸造装备与技术
[24] 铸造有色合金及其熔炼联合编写组,铸造有色合金及其熔炼.北京,国防工业出版社
[25] 施廷藻,王玉玮 ,铸造实用手册,东北大学出版社,1994
[26] ENTWISETJE R A ,GRUZLESKI J E and THOMAS P KM .Development of porosity in aluminum base alloys(J).AFS Trans .1977,85:345~349
[27] Leonhard Maier, HU Pei, Herman Seibert. PMI Foam Cored Sandwich Components Produced by Means of Different Manufacturing Methods, JOURNAL OF MATERIALS ENGINEERING, 2006. 5: P 37-40, 45
[28] 冯炳尧 蒋文森等,模具设计与制造简明手册,上海科学技术出版社,1985
[29] 机械工业出版社,铸造有色合金及其熔炼,1978
[30] 中国机械工程学会铸造分会,铸造手册(第四卷)造型材料.北京:机械工业出版社.2002
[31] Wu Tonghai, Diao Dongfeng, Xie Youbai. INVESTIGATION ON FRACTAL CHARACTERISTICS OF WORN SURFACES OF POLYMER TAPES BY SAND DUST PARTICLES. ACADEMIC JOURNAL OF XI’AN JIAOTONG UNIVERSITY, 2006.18.1: P17-20
[32] 影响覆膜砂性能的因素 ,刘满平 袁锡爵 ,铸造工程.造型材料-1999:23(1)-22-24
[33] 覆膜砂工艺参数优化的研究 ,梁春永 王磊李 海鹏 李刚 ,中国铸造装备与技术-2007(6)-28-31
[34] BERRY J T .Effects of solidification conditions on mechanical behavior of AL cast alloys(J).AFS Trans.1970 ,78:421~428.
[35] Davies G J 著,凝固与铸造.陈邦迪,舒震译.北京:机械工业出版社.
[36] KUTUMBA Rao G V.Action of chills on solidification and soundness of aluminum-copper-siloicon alloy castings (D).Ph.D.Thesis IIL Madras.1972.
[37] 史密斯 W F.工程材料的组织与性能。北京:冶金工业出版社.1984.
[38] 中国机械工程学会铸造分会,铸造手册(第三卷)铸造非铁合金.北京:机械工业出版社.2002
[39] IRANI D R and KONDIC V .Casting and mold design effects on shrinkage,porosity of light alloys(J).AFS Trans.1969,77:208~211.
[40] 激冷覆膜砂的开发与应用 ,兰顺富 ,造型材料-2005:29(4)-21-21
[41] 铬铁矿砂影响铸造收缩的初探 ,徐小玲 ,铸造工程.造型材料-2000:24(3)-33-34
[42] 机械工业出版社出版,铸造技术数据手册.1996.
[43] 机械工业出版社,机械制造工艺材料技术手册,1992
[44] 自制水基石墨涂料的优化 ,廖海滨 牟相山 徐文渊 ,山东冶金-2005:27(3)-
[45] 蔡震升等,实用铸造耐火材料.冶金工业出版社.
[46] PAN Zhihua, Fujiwara Hiromi, Wee Tionghuan. Preparation of HighPerformance Foamed Concrete from Cement, Sand and Mineral Admixtures, JOURNAL OF WUHAN UNIVERSITY OF TECHNOLOGY. MATERIALS SCIENCE EDITION , 2007.22.2: P295-298
[47] 严兆大,王振子,俞小莉,热能与动力机械测试技术,机械工业出版社,2004
[48] 沙占友编著,内燃机测试仪器的原理与维修.北京.国防工业出版社,1985
[49] 吴克刚,曹建民,发动机测试技术.人民交通出版社.2002
[2] 赵英,中国汽车工业发展趋势及对策,2006
[3] Chen Yong, Chen Quanshi, Sun Fengchun. Motion Analysis of an Electric Vehicle with Two Independent Drive Motors, JOURNAL OF BEIJING INSTITUTE OF TECHNOLOGY, 2004.13.1: P109-112
[4] Zhao Xuhong. How far can China's motors driver in the international market?. CHINA'S FOREIGN TRADE, 2003.9: P16-17
[5] 腾逸风,发动机新技术及发展趋势,2006
[6] Heinz Heisler.Advanced Engine Technology.London Edward Amold.1995.
[7] S.A.Niemi,J.A.Pit Kanen and J.B.Tamminen.Development of Different Neat Ethanol Driven Direct-Injection Truck and Tractor Engines.X ISAF vol.I,478~491.Colorado 1993.
[8] H.Hong,T.Krepec and R.M.H.Cheng.Optimization of Electronically Controlled Injectors for Direct Injection of Natural Gas in Diesel Engines.
[9] Michael Walsh.Globle Treds in Diesel Particutlate Control –A 1995 Update.SAE 950149.
[10] Kiyoshi Hatono,Kazumasa Lida,Hirohumi Higashi and Shinichi Murata.Development of New Multi-Mode Variable Valve Timing Engine.
[11] Naoto Miyoshi,Naoki Takahashi,Kouichi Kasahara and et al.Development of New Concept Three Catalyst for Automotive Lean –Burn Engines.SAE 950809.
[12] B.Pfalzgraf,E.Otto.A Wirth,and et al .The System Development of Electrically Heated Catalyst(EHC) for The LEV and EU Ⅲ Legislation. Audi AG,bmw ag,1995.
[13] Martin J.Heimrich,Lawrence R .Smith,and Jack Kitowski.Cold-startHydrocarbon Collection for Advanced Exhaust Emission control.SAE920847.
[14] 陈培陵,汽车发动机原理.北京,人民交通出版社,2004
[15] 浅析发动机进气系统,中华建筑机械网,2006
[16] 汽车工程手册 设计篇 .人民交通出版社.2001
[17] 贺礼清, 工程流体力学.石油工业出版社. 2004
[18] 周龙保、刘巽俊、高宗英,内燃机学. 机械工业出版社,1999 年 5 月,第 1 版,(215)
[19] 于洪水,发动机与汽车原理.北京大学出版社.2005
[20] 高延龄,汽车应用工程.北京,人民交通出版社,1999
[21] 倪计民等,电喷汽油机可变进气系统的优化设计
[22] 范守宏,试论我国汽车有色铸件的发展,中国铸造装备与技术 5/2006
[23] 李玉青,吴殿杰,铸件轻量以及铝镁铸件的应用.4/2005 中国铸造装备与技术
[24] 铸造有色合金及其熔炼联合编写组,铸造有色合金及其熔炼.北京,国防工业出版社
[25] 施廷藻,王玉玮 ,铸造实用手册,东北大学出版社,1994
[26] ENTWISETJE R A ,GRUZLESKI J E and THOMAS P KM .Development of porosity in aluminum base alloys(J).AFS Trans .1977,85:345~349
[27] Leonhard Maier, HU Pei, Herman Seibert. PMI Foam Cored Sandwich Components Produced by Means of Different Manufacturing Methods, JOURNAL OF MATERIALS ENGINEERING, 2006. 5: P 37-40, 45
[28] 冯炳尧 蒋文森等,模具设计与制造简明手册,上海科学技术出版社,1985
[29] 机械工业出版社,铸造有色合金及其熔炼,1978
[30] 中国机械工程学会铸造分会,铸造手册(第四卷)造型材料.北京:机械工业出版社.2002
[31] Wu Tonghai, Diao Dongfeng, Xie Youbai. INVESTIGATION ON FRACTAL CHARACTERISTICS OF WORN SURFACES OF POLYMER TAPES BY SAND DUST PARTICLES. ACADEMIC JOURNAL OF XI’AN JIAOTONG UNIVERSITY, 2006.18.1: P17-20
[32] 影响覆膜砂性能的因素 ,刘满平 袁锡爵 ,铸造工程.造型材料-1999:23(1)-22-24
[33] 覆膜砂工艺参数优化的研究 ,梁春永 王磊李 海鹏 李刚 ,中国铸造装备与技术-2007(6)-28-31
[34] BERRY J T .Effects of solidification conditions on mechanical behavior of AL cast alloys(J).AFS Trans.1970 ,78:421~428.
[35] Davies G J 著,凝固与铸造.陈邦迪,舒震译.北京:机械工业出版社.
[36] KUTUMBA Rao G V.Action of chills on solidification and soundness of aluminum-copper-siloicon alloy castings (D).Ph.D.Thesis IIL Madras.1972.
[37] 史密斯 W F.工程材料的组织与性能。北京:冶金工业出版社.1984.
[38] 中国机械工程学会铸造分会,铸造手册(第三卷)铸造非铁合金.北京:机械工业出版社.2002
[39] IRANI D R and KONDIC V .Casting and mold design effects on shrinkage,porosity of light alloys(J).AFS Trans.1969,77:208~211.
[40] 激冷覆膜砂的开发与应用 ,兰顺富 ,造型材料-2005:29(4)-21-21
[41] 铬铁矿砂影响铸造收缩的初探 ,徐小玲 ,铸造工程.造型材料-2000:24(3)-33-34
[42] 机械工业出版社出版,铸造技术数据手册.1996.
[43] 机械工业出版社,机械制造工艺材料技术手册,1992
[44] 自制水基石墨涂料的优化 ,廖海滨 牟相山 徐文渊 ,山东冶金-2005:27(3)-
[45] 蔡震升等,实用铸造耐火材料.冶金工业出版社.
[46] PAN Zhihua, Fujiwara Hiromi, Wee Tionghuan. Preparation of HighPerformance Foamed Concrete from Cement, Sand and Mineral Admixtures, JOURNAL OF WUHAN UNIVERSITY OF TECHNOLOGY. MATERIALS SCIENCE EDITION , 2007.22.2: P295-298
[47] 严兆大,王振子,俞小莉,热能与动力机械测试技术,机械工业出版社,2004
[48] 沙占友编著,内燃机测试仪器的原理与维修.北京.国防工业出版社,1985
[49] 吴克刚,曹建民,发动机测试技术.人民交通出版社.2002