CN101920433A - Method for processing core component of energy-saving muffler of internal combustion engine - Google Patents
Method for processing core component of energy-saving muffler of internal combustion engine Download PDFInfo
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- CN101920433A CN101920433A CN2010101756732A CN201010175673A CN101920433A CN 101920433 A CN101920433 A CN 101920433A CN 2010101756732 A CN2010101756732 A CN 2010101756732A CN 201010175673 A CN201010175673 A CN 201010175673A CN 101920433 A CN101920433 A CN 101920433A
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
Abstract
The invention belongs to the technical field of manufacturing of mufflers of exhaust systems of internal combustion engines and relates to a method for processing and manufacturing a core component of the muffler of the exhaust system of the internal combustion engine. In order to meet the urgent demands of abroad and domestic automobile market for energy-saving and emission-reducing mufflers, the core component of the energy-saving muffler of the invention is prepared by punching and molding high-temperature resistant, weak-acid resistant and high-phosphorus steel sheets with a certain shape and a certain thickness by using female and male dies under a hydraulic pressure at one time, wherein the core component is shown in a figure 3 (the figure 3 has a peak A and is a top view formed by four connected parts each of which consists of an inner wind cone (mark 3), a main wind block (mark 1) and a wind distributing block (mark 2)). Compared with the method for processing and manufacturing the core component of the energy-saving muffler in the authorized invention patent named 'energy-saving muffler of exhaust system of internal combustion engine' (ZL200410010261.8), the method of the invention has the advantages that: production efficiency is improved by 10 times; and product quality is more stable. The method for processing the core component of the large-scale, superlarge-scale and huge-scale energy-saving muffler adopts a precision casting (lost-wax process) preferably and then performs program control on a vertical lathe and a vertical milling machine; and a small amount of core components of the large-scale muffler with high precision requirement also can be processed by a powder metallurgy method.
Description
Technical field
The invention belongs to internal combustion engine exhaust system muffler manufacturing technology field, be specifically related to the machining manufacture of internal combustion engine exhaust system muffler core component.
Background technology
The world today all with the internal combustion engine be power car and boat must join muffler principle all be the combination of anti-formula, resistance formula or its two kinds of principles, no matter and its service life short (the national regulation muffler: lorry uses 1 year, car to use 2 years), consumptive material many (ZL 200410010261.8 patents relatively), muffler gradually stifled when making disposal of pollutants is gradually big, it is gradually stifled exhaust resistance force power of IC engine merit damage to reach 20%--25% muffler scrap.As figure one (anti-formula muffler schematic diagram), except that air inlet pipe, tail pipe, muffler tube, its internal core assembly is dividing plate, conduit or buzzing pipe, if it is combined with resistance formula principle, still there is basalt cotton to add stainless steel wool etc., this core component (the parcel world today all with the internal combustion engine be power car and boat must join the core component of muffler, also be wrapped in disclosed those 664 mufflers of China, silencing means patent.) can not punching press success.
2. the patent of invention of having authorized [internal combustion engine exhaust system energy-saving muffler] (ZL 200410010261.8) is on structure: artificial divides wind facies to hit exhaust waste gas, these two strands of air quantity are the same, the array that direction is opposite is carried different audio frequency, the noise particulate of different-energy carries out effective audio feedback (same frequency resonance) continuously in hollow muffler tube, promptly greatly reducing noise makes exhaust very smooth again, never stop up, energy-saving and emission-reduction, improve muffler service life more than 5 times by GB, though this invention has been captured the top difficult problem in the world in muffler field (as figure two from structure, figure three), but the described machining manufacture of this patent can not satisfy market in urgent need, (this is invented in the 10th page 2 machining manufacture is described below: weld inner cone seam and with the mould effect of necessity just after can utilizing the concavo-convex mould of shaping size and building-block machine thereof once to roll out with the material of identical material respective thickness to wind awl and cardinal wind block and the wind dispersing block of typing again, the cardinal wind block wind dispersing block can be gone out with corresponding sheet material to small batch that to bore the arc positions with two dormant bolt wind of living in it fastening again.) because after its core component once rolls out blank with the steel plate section bar, weld again in the special-purpose welding clamp that must be contained in certain preload pressure when inner cone stitches and to weld the inner cone seam, this core component of energy-saving muffler is only under the situation of high investment, automation volume, folder, weldering, effect can realize, but compare with following the present invention is one time punching molded, be on productivity ratio, product quality stable go up and cost on all can't fly wing to wing.
Summary of the invention
1 summary of the invention:
The objective of the invention is to improve the internal combustion engine exhaust system core component of energy-saving muffler productivity ratio, improve the quality of products, save production cost, the present invention can be with core component of energy-saving muffler, produce in enormous quantities with one-time formed pressure processing method, satisfy the urgent need to the energy-saving and emission-reduction muffler such as domestic and international automobile market rapidly.
2 specific embodiment:
ZL 200410010261.8 core component of energy-saving muffler such as figure three, figure three is that the summit is that A bores (mark 3) by interior wind, vertical view after three kinds of other parts of cardinal wind block (mark 1) and wind dispersing block (mark 2) are connected, with concavo-convex mould figure three is used definite shape, certain thickness high temperature resistant, weak acid resistant high phosphorus steel board is in the punch forming next time of fluid pressure machine, (according to annual production, the required precision of core component, hush pipe cross section size, cardinal wind block and wind dispersing block level of stretch, the quantity of cardinal wind block and wind dispersing block, the operating temperature of core component, the security of press operation, the difference of atomization degree etc. can be selected different pressures, the forcing press of different operating principle, parcel fluid pressure machine, high-speed blanking press and automatic transfer press.The present invention stresses to describe the machining manufacture of the higher core component of energy-saving muffler of moderate-yield, the cross-sectional area of similar middle-grade car muffler, required precision.) technological process is as follows:
A. the qualification test of core component of energy-saving muffler:
Satisfy country to the basis of specifying car type exhaust noise standard-required on, must test out: the muffler of resistance relatively, anti-(or resistance, anti-combination) principle, energy-conservation more than 15%, improve the sample of a discharge standard relatively.
B. according to the one-time formed stamped female punch of successful sample design core component of energy-saving muffler:
Under situation according to parameter constants such as successful sample air-out angle bus, air outputs, for the better demoulding and metal plastic deformation, cardinal wind block and wind dispersing block are carried out unconventional increasing pattern draft (8 degree-18 degree), strengthen the fillet design that cardinal wind block and wind dispersing block and interior wind awl are connected fillet partly and strengthen cardinal wind block and wind dispersing block self.
C. core component of energy-saving muffler summit A place (figure three) are designed to semicircle spherical (to cylinder) or semiellipse spherical (to cylindroid):
Its R is by towards the 2--5 of heat-resisting, weak acid resistant high phosphorus steel plate thickness doubly.
D. the pressurize of core component of energy-saving muffler with cut overlap:
In concavo-convex mould because by towards steel plate 100% plastic deformation, area greater than 1/3 is stretched, consider the metallic elastic coefficient of high phosphoretic steel, workpiece in concavo-convex mould must by pressurize 2--3 second eliminating internal stress and elastic force, overlap is cut and enter automatic separated flow waterline with workpiece after the while demoulding moment before the pressurize.
E. the processing of core component of energy-saving muffler stamped female punch:
According to production lot, work piece material and the size of thickness and workpiece, selected press etc., should be earlier preferred corresponding mould steel, the operation of being left: rough forge, half finish forge, annealing, carry out thick finish turning, (the program control thick finish turning of palpus of joining cylindroid), program control thick finish-milling, nitrizing quenching, normalizing, program control thick correct grinding, the check of red lead impression, installation according to the design drawing of concavo-convex mould and examine, add antirust oil with the steel plate pressurization of appointment is whole with pressurize initial survey, installation of aluminium sheet.
F. to processing method large-scale, super-huge, huge core component of energy-saving muffler:
Common automobile, tractor muffler tube mid diameter are between the 80--480mm, the all available one-time formed pressure processing method of its core component of energy-saving muffler is produced in enormous quantities, directly should be large-scale, straight warp and surpasses 1800mm and should be huge (as the muffler of ocean palace muffler, 300MW gas turbine etc.) through surpassing 600mm.These large-scale, super-huge, the huge muffler whole world only need several ten thousand to overlap every year.Super-huge, the huge core component of energy-saving muffler of supply and demand below several thousand should preferentially be selected the method for hot investment casting for use, and then program-controlled vertical lathe and program control vertical milling; Precision prescribed height and the large-scale energy-saving muffler core component of small lot also can be selected powder metallurgy method for use, the former technology are the meticulous concavo-convex wooden models of processing, and the latter process selects for use superior alloy steel to process meticulous concavo-convex die according to the character of iron powder.Design and processing to concavo-convex wooden model, concavo-convex die, equally for the better demoulding and metal plastic deformation (or metal flow), cardinal wind block and wind dispersing block are carried out unconventional increasing pattern draft equally, strengthen be connected with the interior wind awl fillet of fillet, increasing cardinal wind block and wind dispersing block self of part of cardinal wind block and wind dispersing block and design; Equally A place, muffler core component summit is designed to semicircle spherical (to cylinder) or semiellipse spherical (to cylindroid): its R according to the thickness of wind awl and workpiece directly through selection, when general wind was bored thickness less than 6mm, R got the straight 1/15-1/50 through (or mid diameter) of workpiece.
3. beneficial effect:
A. China is that world car is produced first big country, produces 1379 ten thousand per year in 2009, surpasses the then summation of Japan and the United States two countries auto output. China's fuel oil degree of self-sufficiency less than 50%, the strategic materials of saving this day hardship having exhausted, price skyrockets are the most important things in the various countries leaders energy policy. The patent of invention of having authorized [energy saving muffler of exharst] through 6 years, many car types, reach 500,000 kilometers road examination, although average fuel-economizing 15% also improves a discharge standard, its core component productivity ratio is very low: on transfer matic, only produced in per 40 seconds a cover (windward is emitted the shear punching press 5 seconds, core component shear 3 seconds, core component volume press contain cut overlap 10 seconds, enter weldering inner cone seam anchor clamps 8 seconds, anchor clamps upset 3 seconds, robot automatic welding 3 seconds, pressurize imitate positive 5 seconds, emitted pressure welding 3 seconds with windward). With the bright processing method of this law the 23%--28% of said method investment (only for), on transfer matic, produced a cover in per 15 seconds and (windward is emitted the shear punching press 5 seconds, core component shear 3 seconds, core component punching press and pressurize 4 seconds, emitted pressure welding 3 seconds with windward. ) gross efficiency (containing investment) improves about 10 times. With the bright processing method of this law, just can satisfy the renewal of domestic that 1.5 hundred million car and boat recoverable amounts (containing tractor, motorcycle etc.) energy-saving muffler less than the times in 3 years, the annual minimum fuel oil of saving takes 1,200 hundred million yuan till that time, and the Chinese fuel oil degree of self-sufficiency at that time will drop to 35--38%.
B. promote the well-being of mankind: the world car recoverable amount will reach 1,000,000,000 in 2010, and China also will reach 7,000 ten thousand. The bright 10 times of ground of this law have accelerated the conversion of [energy saving muffler of exharst] patent of invention, by 2.28 tons of the average annual oil consumption of each automobile in 2003, save 15% fuel oil, just save 3.42 hundred million tons for 1,000,000,000; Just can save 2,633 ten thousand tons for 7,000 ten thousand.
Description of drawings
Figure one is anti-formula muffler schematic diagram.
Figure two is the schematic diagrames after the assemblings such as patent of the present invention and hush pipe, and wherein 1 is the cardinal wind block of a shaped by fluid pressure, and 2 is the wind dispersing block of a shaped by fluid pressure, and 3 is the branch wind passage of a shaped by fluid pressure formation, and the A point is the summit of core component of the present invention.
Figure three is schematic top plan view of the core component of energy-saving muffler of a shaped by fluid pressure of the present invention, 1,2,3, described in A point such as the figure two.
Claims (6)
1. the qualification test of core component of energy-saving muffler:
Satisfy country to the basis of specifying car type exhaust noise standard-required on, must test out: the muffler of resistance relatively, anti-(or resistance, anti-combination) principle, energy-conservation more than 15%, improve the sample of a discharge standard relatively.
2. according to the one-time formed stamped female punch of successful sample design core component of energy-saving muffler:
Under situation according to parameter constants such as successful sample air-out angle bus, air outputs, for the better demoulding and metal plastic deformation, cardinal wind block and wind dispersing block are carried out unconventional increasing pattern draft (8 degree-18 degree), strengthen the fillet design that cardinal wind block and wind dispersing block and interior wind awl are connected fillet partly and strengthen cardinal wind block and wind dispersing block self.
3. core component of energy-saving muffler summit A place (figure three) are designed to semicircle spherical (to cylinder) or semiellipse spherical (to cylindroid):
Its R is by towards the 2--5 of heat-resisting, weak acid resistant high phosphorus steel plate thickness doubly.
The pressurize of core component of energy-saving muffler with cut overlap:
In concavo-convex mould because by towards steel plate 100% plastic deformation, area greater than 1/3 is stretched, consider the metallic elastic coefficient of high phosphoretic steel, workpiece in concavo-convex mould must by pressurize 2--3 second eliminating internal stress and elastic force, overlap is cut and enter automatic separated flow waterline with workpiece after the while demoulding moment before the pressurize.
5. the processing of core component of energy-saving muffler stamped female punch:
According to production lot, work piece material and the size of thickness and workpiece, selected press etc., should be earlier preferred corresponding mould steel, the operation of being left: rough forge, half finish forge, annealing, carry out thick finish turning, (the program control thick finish turning of palpus of joining cylindroid), program control thick finish-milling, nitrizing quenching, normalizing, program control thick correct grinding, the check of red lead impression, installation according to the design drawing of concavo-convex mould and examine, add antirust oil with the steel plate pressurization of appointment is whole with pressurize initial survey, installation of aluminium sheet.
6. to processing method large-scale, super-huge, huge core component of energy-saving muffler:
Straight large-scale, the straight warp that should be through surpassing 600mm of core component of energy-saving muffler surpasses 1800mm and should be huge (as the muffler of ocean palace, 300MW gas turbine etc.).Super-huge, huge core component of energy-saving muffler should preferentially be selected hot investment casting (lost-wax process) for use, and then program-controlled vertical lathe and program control vertical milling; Precision prescribed height and the large-scale energy-saving muffler core component of small lot also can be selected powder metallurgy method for use, the former technology are the meticulous concavo-convex wooden models of processing, and the latter process selects for use superior alloy steel to process meticulous concavo-convex die according to the character of iron powder.Design and processing to concavo-convex wooden model, concavo-convex die, equally for the better demoulding and metal plastic deformation (or metal flow), cardinal wind block and wind dispersing block are carried out unconventional increasing pattern draft equally, strengthen be connected with the interior wind awl fillet of fillet, increasing cardinal wind block and wind dispersing block self of part of cardinal wind block and wind dispersing block and design; Equally A place in summit is designed to semicircle spherical (to cylinder) or semiellipse spherical (to cylindroid): directly through selecting, general wind awl thickness is during less than 6mm according to the thickness of wind awl and workpiece for its R, and R gets the 1/15-1/50 of the straight warp of workpiece (or mid diameter).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN2010101756732A CN101920433B (en) | 2010-05-12 | 2010-05-12 | Method for processing core component of energy-saving muffler of internal combustion engine |
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| Application Number | Priority Date | Filing Date | Title |
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| CN2010101756732A CN101920433B (en) | 2010-05-12 | 2010-05-12 | Method for processing core component of energy-saving muffler of internal combustion engine |
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| Publication Number | Publication Date |
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| CN101920433A true CN101920433A (en) | 2010-12-22 |
| CN101920433B CN101920433B (en) | 2013-06-12 |
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| CN2010101756732A Active CN101920433B (en) | 2010-05-12 | 2010-05-12 | Method for processing core component of energy-saving muffler of internal combustion engine |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102756239A (en) * | 2012-07-02 | 2012-10-31 | 浙江方宏空调设备有限公司 | Method for manufacturing silencers for automotive air conditioners |
| CN103834884A (en) * | 2014-03-12 | 2014-06-04 | 西南铝业（集团）有限责任公司 | Method and mold for manufacturing die forging and eliminating residual stress |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2158878A (en) * | 1984-05-03 | 1985-11-20 | Dixon Racing Limited | Exhaust silencer |
| JPH10238333A (en) * | 1997-02-25 | 1998-09-08 | Satoshi Nakazawa | Muffler with conical partition wall |
| CN2312330Y (en) * | 1997-10-31 | 1999-03-31 | 石亚西 | Exhaust silencing apparatus for internal combustion engine |
| US5962822A (en) * | 1998-06-23 | 1999-10-05 | May; Daniel A. | Muffler/exhaust extractor and method |
| CN1696478A (en) * | 2004-05-14 | 2005-11-16 | 蒋爱臣 | Energy saving muffler of exharst system in internal-combustion engine |
-
2010
- 2010-05-12 CN CN2010101756732A patent/CN101920433B/en active Active
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB2158878A (en) * | 1984-05-03 | 1985-11-20 | Dixon Racing Limited | Exhaust silencer |
| JPH10238333A (en) * | 1997-02-25 | 1998-09-08 | Satoshi Nakazawa | Muffler with conical partition wall |
| CN2312330Y (en) * | 1997-10-31 | 1999-03-31 | 石亚西 | Exhaust silencing apparatus for internal combustion engine |
| US5962822A (en) * | 1998-06-23 | 1999-10-05 | May; Daniel A. | Muffler/exhaust extractor and method |
| CN1696478A (en) * | 2004-05-14 | 2005-11-16 | 蒋爱臣 | Energy saving muffler of exharst system in internal-combustion engine |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102756239A (en) * | 2012-07-02 | 2012-10-31 | 浙江方宏空调设备有限公司 | Method for manufacturing silencers for automotive air conditioners |
| CN102756239B (en) * | 2012-07-02 | 2015-07-08 | 浙江方宏空调设备有限公司 | Method for manufacturing silencers for automotive air conditioners |
| CN103834884A (en) * | 2014-03-12 | 2014-06-04 | 西南铝业（集团）有限责任公司 | Method and mold for manufacturing die forging and eliminating residual stress |
| CN103834884B (en) * | 2014-03-12 | 2015-12-30 | 西南铝业（集团）有限责任公司 | A kind ofly manufacture stamp work and eliminate method and the mould of unrelieved stress |
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| CN101920433B (en) | 2013-06-12 |
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